Experimental Investigations of the Effect of Various Gating Systems in Aluminum Casting Process

Abstract

This paper presents a systemic study of the effect of different cross section of gate in permanent mold casting of aluminium alloy. To ensure best quality of the product they would cavity must be filled with clean metal in a controlled manner to ensure smooth, uniform and complete filling. A gating system controls smooth, uniform and complete filling of the cavity by the molten metal. In this paper, CFD models illustrating the effect of rectangular and trapezium cross sections of gating on cooling of Aluminium alloy in a permanent mold casting were investigated. Same hydraulic diameter was assigned for each of the cross section of gating systems. Bottom gating system is used for its low gas entrapment and less surface defect characteristics. By analyzing it has been observed that in rectangular cross section the cooling is more rapid than trapezium cross sections considered in the investigation. Besides that aluminum castings have played an integral role in the growth of the aluminum industry since its inception in the late 19th century. The first commercial aluminum products were castings, such as cooking utensils and decorative parts, which exploited the novelty and utility of the new metal. Those early applications rapidly expanded to address the requirements of a wide range of engineering specifications. Alloy development and characterization of physical and mechanical characteristics provided the basis for new product development through the decades that followed. Casting processes were developed to extend the capabilities of foundries in new commercial and technical applications. The technology of molten metal processing, solidification, and property development has been advanced to assist the foundry man with the means of economical and reliable production of parts that consistently meet specified requirements.