• A novel gas generation and flow constitution model integrates temperature-dependent gas evolution with Darcy's law, enabling accurate simulation of gas pore formation in iron castings.
• The virtual heat transfer method effectively identifies dangerous core regions by leveraging the analogy between heat and gas flow, reducing computational cost.
• The model predicts gas pore risk based on gas pressure, melt viscosity, and state, validated by three distinct sand core designs in actual iron castings.
• This approach provides a practical tool for optimizing sand core venting and reducing leakage defects in high-integrity castings like cylinder blocks and heads.