Patent ID: 8655476

Claim:
A method of computationally simulating a casting process for a lightweight metal alloy-based component, said method comprising: configuring a computer to comprise a data input, a data output, a processing unit, a memory unit and a communication path for cooperation between said data input, said data output, said processing unit and said memory unit; and operating said computer with a plurality of computation modules programmably cooperative with at least one of said memory unit and said processing unit such that upon receipt of data pertaining to said component, said computer subjects said data to said plurality of computation modules such that output therefrom provides performance indicia of said casting process, said plurality of computation modules comprising: a casting design module configured to provide an optimized geometric representation of said component; a process optimization module configured to determine at least one of a casting process, heat treating and machining of said final casting design; a multiscale microstructure prediction module configured to accept as input thereto data from said casting design module and said process optimization module in order to produce as output material characteristics, defect population estimates for a plurality of defect types, and microstructural architecture over a plurality of size scales; and a structure performance module configured to accept said material characteristics, defect population estimates and microstructural architecture output along with loading conditions, a predicted residual stress and distortion and a durability test simulation to produce said performance indicia.