Integrating prestress simulation and literature insights to assess mold design effects in sand-cast components

Purpose This study aims to evaluate the residual stress distribution and structural performance of as-cast EN-GJS-600-3 nodular iron components by integrating a prestress simulation algorithm with microstructural and mechanical analysis. Specifically, it explores how mold design parameters affect thermal gradients, stress homogeneity and defect sensitivity, thereby influencing casting reliability. The goal is to establish a framework that connects mold-induced thermal behavior with stress localization and fracture risk, ultimately supporting design improvements in sand casting processes. Design/methodology/approach The Adjacent Element Temperature-Driven Prestress Algorithm (AETDPA) was employed to simulate residual stress fields based on solidification-induced thermal gradients. Two regions from geometrically similar cast parts were evaluated using tensile testing and microstructural characterization. The methodology involved correlation of stress zones with graphite morphology, enabling assessment of stress-microstructure interaction. Mold design variables such as runner layout were analyzed to understand their influence on stress homogeneity. Simulation results were compared with experimental data to validate the predictive accuracy of the approach. Findings The study found that residual stress distributions vary significantly within nominally identical castings due to localized thermal gradients and mold layout. Regions with higher pearlite content exhibited more homogeneous stress patterns and improved mechanical performance. AETDPA effectively predicted fracture-prone zones, with strong correlation between stress concentrations and microstructural features. Experimental tensile tests confirmed that stress-simulated zones aligned with actual fracture sites, validating the simulation methodology as a tool for structural reliability prediction in cast components. Originality/value This work presents a novel integration of thermal-based prestress simulation with mold design analysis and microstructural validation, bridging a critical gap in casting research. Unlike traditional studies that treat microstructure and stress separately, this approach connects process-induced prestress with mechanical outcomes. It introduces a simulation-based method to evaluate mold layout not only for defect minimization but also for stress homogenization. The framework supports more reliable sampling, testing and design adjustments in casting, offering a predictive tool for both researchers and practitioners focused on improving sand-cast component performance.