The objective of the project is to provide a basis for improved gating design for vertically-parted aluminum permanent mold castings.
The design of gating for conventional gravity-fed vertically-parted permanent mold castings is a task which is performed daily throughout the foundry industry, but for which there is a great deal of dissatisfaction with the current design methodology and recommended gating designs. Basic gating design has remained essentially unchanged since the mid 1950ís.
This program will examine the gating of vertically-parted aluminum permanent mold castings through a combination of experiments and computer simulations to develop improved gating designs. The improved gating systems will aim to eliminate molten metal surface turbulence during mold filling in order to reduce casting defects, maximize thermal gradients during solidification to aid metal feeding, provide necessary risers as a source of feed metal, and maximize casting yield by minimizing gating and riser size. Through improved gating design, castings can be produced with higher casting yields, lower scrap rates, lower defect contents, and with fewer initial design iterations.