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As the filling of the component was observed to last longer than normal, the engineers started wondering if the component was not delivered with material defects (Figure 3). This view was supported by analysing the as-cast surface condition of the component (Figure 3). Close examination of the surface revealed that a surface defect (Figure 5) was observed. This was observed to be a visible keyhole defect. The keyhole defects are typically formed when two or more grains of material are held together by a reactional liquid, which coalesce, leaving a visible crack in the cast. The liquid is drawn into the crack, and the grain is mechanically redistributed. The grain is locked in the crack and separates from the bulk, becoming a keyhole defect. If the component is cast with a yield strength of 2,000 MPa, a grain size of 0.1-0.5 mm in width is considered by the engineers to be the minimum threshold of size. This left the engineers puzzled, as the initial assessment had shown the component to have a yield strength of 3,000 MPa.
The surface condition of the component showed it to have some fine cracks, grain boundaries and surface defects. This was made more evident by analysing the micrographs (Figure 6). Here, the engineers were able to clearly discern that the surface of the cast was composed of overlapping grains. These fields of grains were analysed to find the fractions of the grain boundary (Figure 6a) in the whole cast (Figure 6b). This analysis showed that the grains averaged about 0.5mm across. Wider grains of up to several millimetres were observed. The thickness of the grains ranged in size from 0.1mm to 0.5mm. This allows us to deduce that the grain size was within 0.1mm of the smallest grain, as any grain bigger than this could not have created a defect of the surface, as the edge along the grain boundary would have remained closed.
For the next step, the engineers decided to focus only on optimising the component to include only one of the three objectives. In the previous section, it was shown that the filling time could not exceed 12 seconds to ensure optimal productivity. Therefore, the engineers were forced to neglect the cost (0. d2c66b5586