Abstract A three-phase model is presented that predicts solid deformation and damage as well as melt pressure, feeding flow and shrinkage porosity during metal casting. A visco-plastic constitutive theory with damage is used to model the solid deformation. Damage created by mechanically induced voiding is used as a hot tear indicator. The absence of liquid feeding determines when damage starts to form. The model has been implemented in general-purpose simulation codes. Novel steel casting experiments have been designed and performed which measure the deformation and force from solidification to shakeout. The measured and predicted deformations show generally good agreement with the simulation results. Furthermore, the damage predictions show good correspondence with hot tear indications on a radiograph of the test casting
