AbstractOn solidification, microsegregations build up in solid phases due to changes in solid concentrations with temperature. Diffusion, which is a kinetic process, usually reduces the occurrence of microsegregations. This work is aimed at modeling such kinetic effects on the solidification of austenitic cast iron, using a holistic approach. For this purpose, a microsegregation model is developed and validated. Moreover, this model is directly coupled to a commercial process‐simulation tool and thermodynamic software. A series of GJSA‐XNiCr 20‐2 clamp‐rings is cast by varying the inoculation state and the number of feeders. The composition of this cast alloy is analyzed and the microstructure characterized to provide input data for the microsegregation model. In order to validate the software, cooling curves are recorded; differential thermal analysis, electron dispersive X‐ray analysis and electron probe micro analysis are carried out. Furthermore, the porosity within the casting is analyzed by X‐ray. By performing coupled simulations, the different cooling characteristics within the casting lead to pronounced differences in phase fractions and solidification temperatures which are due to dendrite arm coarsening. The hot spot effect below the feeders is assisted by a shift towards lower solidification temperatures over the solidification time. This shift is a result of the local cooling characteristics, which can only be predicted when process simulation is directly coupled with material simulation. The porosity predictions and the porosity analysis exhibit good agreement. A comparison between experimental and virtual cooling curves closes, implying that the novel coupling concept and its implementation are valid.