This review critically examines contemporary modelingModeling methods employed in the assessment of defects in aluminum castingsAluminum castings, with a focus on evaluating plasticity, deformation behavior, and crack initiation phenomena. Advances in experimental characterizationCharacterization, most notably computed tomographyComputed tomography (CT) scanning and optical crack surface analysis, have enabled the precise quantification of internal defect metrics such as defect volume, surface area, and spatial distribution. These high-resolution data sets have paved the way for the integration of sophisticated numerical models, including classical J2 plasticity formulations, the Gurson–Tvergaard–Needleman (GTN) model, and local-scale damage models such as the Beremin model, into finite elementFinite element analysis frameworks. The review synthesizes current literature on the application of these models to simulate the influence of castingCasting defects—such as porosities, bifilmsBifilm, and oxide inclusions—on the mechanical behavior of aluminum alloysAluminum alloy. Special attention is given to the correlation between experimentally measured defect metrics and simulationSimulation predictions of plastic deformation and crack propagation. In addition, the effects of alloying elements and castingCasting process parametersProcess parameter on defect formationDefect formation and subsequent mechanical performance are discussed, highlighting the role of grain refiners (e.g., Ti–V and Nb) in enhancing material propertiesProperties. Finally, the paper identifies current challenges and future research directions, including multiscale modelingModeling approaches that aim to capture defect nucleation, growth, and coalescence with higher predictive accuracyAccuracy. This comprehensive review provides valuable insights for researchers and engineers striving to optimize castingCasting processes and improve the reliability of aluminumAluminum components in industrial applicationsIndustrial applications.