Sequential Structural and Casting Simulation Approach for the Fabrication of Ni–Al–Bronze Submarine Mast Cover

Submarine mast covers are critical cantilever appendages subjected to extreme hydrostatic pressure during submerged transit. To ensure structural reliability and control internal defects inherent in heavy-section casting, an integrated design-to-manufacturing framework sequentially linking structural finite element analysis (FEA), fluid volume method (FVM)-based casting simulation, and full-scale experimental sand casting was established. FEA under a 600 m submergence depth (7.0 MPa hydrostatic pressure) identified stress concentrations on the inner surface along the major-axis section. Introducing an optimized fillet radius at a sharp step reduced peak equivalent stress from 216.0 MPa to below 194.0 MPa, securing a safety factor exceeding 2.0 against the yield strength of nickel–aluminum–bronze (390 MPa). MAGMA5 casting simulations verified an unpressurized bottom-gating system (S:R:G = 1.00:2.88:4.80), achieving smooth laminar filling with gate velocities under 1.25 m/s without cold shuts. To mitigate predicted shrinkage porosity, process modifications enlarging riser diameters from Ø30 mm to Ø60 mm and placing chills were implemented in the actual casting trial, while top porosity was removed via machining allowances. Specimens harvested from the full-scale prototype yielded 757.8 MPa UTS, 392.5 MPa yield strength, 17.9% elongation, and 197 HB hardness.