technique. Fig 4d: Air Entrainment. Fig 4e: Filling time plot (left), and Shrinkage Porosity (right). design needs to be robust for these process variations. The key to this is management of combination of manufacturing parame- ters and study its effect on the part quality. To define correctly these manufacturing parameters and associated combinations, ESI Group has embedded its optimizer PAM-OPT into ProCAST, which could be used to define and pilot manufacturing parameters and Fig 5a: Shows the 3 main finallycontinue to turn Casting Process into zones (boss) which are Industry 4.0. mandatory for this part to be considered porosity free. References [1] Ch. Pequet, M. Gremaud, and M. Rappaz, “Modelling of microporosity, macroporosity, and pipe-phrinkage formation during the solidification of alloys using a mushy-zone refinement method: applications to aluminium alloys”, Met. Mater. Trans., 33A (2002) 2095. [2] I mad Khan, M & Frayman, Yakov & Nahavandi, Saeid. (2012). Modelling of porosity defects in high pressure die casting with a neural network. [3] G. Couturier, and M. Rappaz, “Effect of volatile ele- ments on porosity formation in solidifying alloys”, Mod. Sim. Mater.Sc. Engng., (2005). [4] Wang, LH & Nguyen, T & Savage, G & Davidson, C. (2003). Thermal and flowmodelling of ladling and injection in high pressure die casting process. Inter- national Journal of Cast Metals Research. 16. 409-417. 10.1179/136404603225007863. [5]Karban, Robert. (2000). Theeffects of intensification pressure, gate velocity, and intermediate shot velocity on the internal quality of aluminum die castings. ETD Collection for Purdue University. Fig 5b: Shows the [6] G. Couturier, J.-L. Desbiolles, and M. Rappaz, “A Poro- shrinkage porosity sity Model for Multi-Gas Systems in Multi-Component comparison of simulation Alloys”, MCWASP, Edited by TMS Publ., Warrendale, vs real cut sections for all USA, 2006). the 3 main zones. [7]Tsoukalas, Vasilios. (2003). The Effect of Die Casting Machine Parameters on Porosity of Aluminum Die Castings. International Journal of Cast Metals Research. 15. 581-588. 10.1080/13640461.2003.11819544. [8] S. Dargusch, Matthew & Dour, Gilles & Schauer, N & M. Dinnis, C & M. Savage, George. (2006). The influence of pressure during solidification of high pressure die cast aluminium telecommunications components. Journal of Materials Processing Technology. 180. 10.1016/j. jmatprotec.2006.05.001. [9] N. Obiekea, Kenneth & Y. Aku, Shekarau & S. Yawas, Danjuma. (2014). Effects ofPressure on the Mechanical Properties and Microstructure of Die Cast Aluminum A380 Alloy. Journal of Minerals and Materials Cha- racterization and Engineering. 02. 248-258. 10.4236/ jmmce.2014.23029. [10] G. Couturier and M. Rappaz, “Modelling of porosity formation in multicomponent alloys in the presence of several dissolved gases andvolatile solute elements”, Symposium on Simulation of Aluminum Shape Casting Processing Edited by Qigui Wang TMS Publ., 2006. [11] ESI ProCAST 2018.0 User Manual. Table 1: Summary of all the development steps. N°10 • AVRIL 2019 • 41