The first run tracked smoothly: the metal filled the cavity in milliseconds of simulated time, thermal gradients pulsed through the part, and the predicted solidification front marched like sunrise over the inner channels. But about halfway through the cycle, a red band pulsed across one of the diagnostic plots — a warning Elias had learned to fear. Macro‑segregation flagged on a choke point in the inner channel. In plain terms: a region of the blade was cooling too slowly, and internal solute enrichment risked forming porous pockets.
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