FLOW-3D CAST Specialist Needed for Molten Aluminum Pouring Simulation
Budget / Salary$250–750
TypeFreelance project
LocationRemote
Posted55 minutes ago
Summary
We are developing an industrial aluminum sow casting system and need an experienced FLOW-3D CAST specialist to simulate molten aluminum pouring from a tilting crucible into an open sow mold.
The main objective is to optimize the pouring geometry and tilt motion to reduce splashing and ensure the metal enters the mold throughout the pour.
Scope of Work
Import and prepare geometry provided from SOLIDWORKS.
Model the tilting crucible, pouring spout, molten aluminum, and receiving mold.
Simulate the pour from initial discharge through mold filling.
Evaluate stream trajectory, impact location, turbulence, and metal escaping outside the mold.
Compare agreed variations in pivot location, spout-to-mold position, drop height, and tilt speed.
Recommend practical changes supported by the simulation results.
We want to begin with one baseline simulation, followed by a small number of design comparisons. Please price the baseline and additional variations separately.
Information We Will Provide
Crucible, spout, mold, and tilter geometry.
Proposed pivot location and motion constraints.
Aluminum alloy, pouring temperature, and initial fill level.
Target pour quantity and filling time.
Available operating measurements or videos.
Please identify any additional inputs you need and clearly document assumptions where information is unavailable.
Required Experience
Hands-on experience with FLOW-3D CAST.
Experience simulating molten aluminum, gravity pouring, and free-surface mold filling.
Ability to model moving pouring equipment and realistic tilt profiles.
Experience evaluating turbulence, surface tension, and air entrainment.
Ability to perform mesh and time-step sensitivity checks and explain the limitations of splash predictions.
Experience with large open molds, ingot casting, or sow casting is preferred.
Deliverables
Simulation animations showing the pouring stream and mold filling.
A concise report comparing the designs, including spill quantity, stream impact location, filling time, and relevant flow results.
Recommended pouring geometry and tilt profile.
Documented material properties, boundary conditions, assumptions, and sensitivity checks.
Complete native FLOW-3D CAST project files, with the software version identified.
The initial priority is pouring and splash behavior. Please quote cooling and solidification analysis separately if you recommend including it.
To Apply
Please provide:
Examples of comparable molten-metal simulations you personally completed.
Your FLOW-3D CAST version and confirmation that you have access to a licensed installation.
Your proposed approach and required inputs.
Your price and turnaround time for the baseline study.
Your price for additional design comparisons.
We are looking for engineering results that can guide equipment design, supported by clear explanations and useful visualizations.
We are developing an industrial aluminum sow casting system and need an experienced FLOW-3D CAST specialist to simulate molten aluminum pouring from a tilting crucible into an open sow mold.
The main objective is to optimize the pouring geometry and tilt motion to reduce splashing and ensure the metal enters the mold throughout the pour.
Scope of Work
Import and prepare geometry provided from SOLIDWORKS.
Model the tilting crucible, pouring spout, molten aluminum, and receiving mold.
Simulate the pour from initial discharge through mold filling.
Evaluate stream trajectory, impact location, turbulence, and metal escaping outside the mold.
Compare agreed variations in pivot location, spout-to-mold position, drop height, and tilt speed.
Recommend practical changes supported by the simulation results.
We want to begin with one baseline simulation, followed by a small number of design comparisons. Please price the baseline and additional variations separately.
Information We Will Provide
Crucible, spout, mold, and tilter geometry.
Proposed pivot location and motion constraints.
Aluminum alloy, pouring temperature, and initial fill level.
Target pour quantity and filling time.
Available operating measurements or videos.
Please identify any additional inputs you need and clearly document assumptions where information is unavailable.
Required Experience
Hands-on experience with FLOW-3D CAST.
Experience simulating molten aluminum, gravity pouring, and free-surface mold filling.
Ability to model moving pouring equipment and realistic tilt profiles.
Experience evaluating turbulence, surface tension, and air entrainment.
Ability to perform mesh and time-step sensitivity checks and explain the limitations of splash predictions.
Experience with large open molds, ingot casting, or sow casting is preferred.
Deliverables
Simulation animations showing the pouring stream and mold filling.
A concise report comparing the designs, including spill quantity, stream impact location, filling time, and relevant flow results.
Recommended pouring geometry and tilt profile.
Documented material properties, boundary conditions, assumptions, and sensitivity checks.
Complete native FLOW-3D CAST project files, with the software version identified.
The initial priority is pouring and splash behavior. Please quote cooling and solidification analysis separately if you recommend including it.
To Apply
Please provide:
Examples of comparable molten-metal simulations you personally completed.
Your FLOW-3D CAST version and confirmation that you have access to a licensed installation.
Your proposed approach and required inputs.
Your price and turnaround time for the baseline study.
Your price for additional design comparisons.
We are looking for engineering results that can guide equipment design, supported by clear explanations and useful visualizations.
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