Foundry & Forging worked example

Casting Solidification Window with available mold-occupancy and cooling window of 23 hr: a worked example

What does the result look like when available mold-occupancy and cooling window reaches 23 hr? The full calculation is worked below with real intermediate numbers. Use it when premature shakeout, delayed knockout, flask availability, or cooling time affects casting quality and throughput.

The inputs for this scenario

  • Available mold-occupancy and cooling window: 23 hr (raised for this scenario; the documented default is 9)
  • Required solidification and cooling time: 6.5 hr (unchanged)
  • Shakeout handling and safety buffer: 1 hr (unchanged)

Working through the calculation

  • Applying the documented formula (Remaining casting solidification window buffer = available cooling or mold window - required solidification and cooling time - handling and safety buffer) to the inputs above produces each figure below.
  • At this operating point the engine returns 0 outside for inside window, the number this scenario is built around.
  • At this operating point the engine returns -16.5 value for nearest margin.
  • At this operating point the engine returns 6.5 value for lower limit.
  • At this operating point the engine returns 1 value for upper limit.

How this compares with the baseline

  • Against the tool's baseline example, where available mold-occupancy and cooling window sits at 9 hr and the headline result is 0 outside, this scenario lands almost exactly on the baseline at 0 outside.
  • A figure at this level is achievable when available mold-occupancy and cooling window is genuinely sustained, not just peaked for a shift. It treats solidification time as a single fixed number; real cooling depends on section thickness, alloy, mold media and ambient conditions, so feed it a verified cooling time from thermal data or trials, not a guess.

Results at a glance

  • Inside window: 0 outside (headline result)
  • Nearest margin: -16.5 value
  • Lower limit: 6.5 value
  • Upper limit: 1 value

Run it with your numbers

  • Every input above is editable in the live Casting Solidification Window calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.