MAVIS-FLOW is a software program for simulating the mould filling and solidification of cast alloys. Developed by Eidawn Software Limited at the University of Wales Swansea the first release of MAVIS was made in 1992. Initially a rapid solidification model was employed for simulating solidification and internal shrinkage defects in sand, investment, gravity die and high pressure die castings. The software was PC based, easy to use, fast and reliable, assets which proved very successful with many UK foundries utilising the software.
Further development of MAVIS resulted in the addition of a numerical solidification simulator being added in 1995. This simulator significantly improved the accuracy of porosity predictions and provided the foundryman with much more data including solidification times, mould temperatures, average steady state die temperature distributions, Niyama coefficients, local freezing times etc. The advantages of numerical simulation are significant compared to rapid models. For the first time foundrymen could simulate the effects of pouring temperature, model long freezing range alloys with confidence and evaluate the effects of transient heat transfer in the mould such as breaker cores.
MAVIS-FLOW was launched in April 2000. This program included a Navier Stokes fluid flow simulator coupled with heat transfer and solidification. This release was the end result of nearly 10 years software development and benchmarking against known test cases, e.g. high pressure water models and 2D real-time X-ray. Many MAVIS users immediately upgraded to this software version and the success of the code when applied to commercial castings by foundrymen was extraordinary. High pressure die-casters were able to predict accurately the filling of moulds and design greatly improved in-gates and overflows. Gravity casters could examine filling in detail to identify problems due to turbulence and design runner systems which produced parts of greater quality. All this coupled with improved shrinkage predictions, thermodynamic freezing models and openGL post processing have ensured that MAVIS-FLOW remains synonymous with the best in foundry focussed simulation design tools.