The Finite Pore Method: a new approach to evaluate gas pores in cast parts by combining computed tomography and the finite cell method

Abstract Although pores are inevitable in casting processes, there is no secured way of evaluating their influence on the performance of cast parts, yet. The durability and dimensioning are both influenced by these discontinuities, therefore it is important to take them into account both for the design process and structural simulations. With the advent of fast and high resolution computed tomography, three-dimensional information concerning the location and the geometry of pores can be obtained. Using these data, we propose a fully automated numerical method to evaluate their influence on the mechanical properties. The current paper illustrates the general idea of how to assess such discontinuities based on voxel (combination of the words volume and pixel (picture element)) or surface tessellation language data using high order fictitious domain methods. The developed methodology provides an insight regarding the stress state of the structure and its life span. The results are used to reduce the costs in the casting process by minimising the number of discarded cast parts.