Design Optimal Riser Size for Reducing Shrinkage Defect in 1100 Aluminum Alloy Sand Casting Process

Abstract:

This research aims to design a sprue system for aluminum castings in sand pores for a basic form prototype in metal casting, which is a one-piece pattern with a parting line. There are several types of liquid metal gating systems available. In the design, variables were specified regarding the height of the sprue, the cross-sectional area of the sprue, the cross-sectional area of the reservoir, the cross-sectional area of the runner, and the cross-sectional area of the gating. The riser size was used as a comparison variable. Following study and design, an experiment was conducted to cast the actual casting and to analyze the behavior simulation using Cast-Designer to determine a solution. In the simulation, the following results were found: the time taken to add liquid metal; the flow behavior of liquid metal; the metal hardening time; and the formation of shrinkage cavities in the casting. Based on the results of casting experiments and behavioral simulations, it was demonstrated that the large riser significantly reduced the shrinkage of the actual casting.

• Periodical: Materials Science Forum (Volume 1129)
• Pages: 61-68
• DOI: https://doi.org/10.4028/p-3RhEBS
• Online since: October 2024
• Authors: Sumethinee Hoochaiyaphum, Pawat Jantasorn, Patpimol Suwankan*
• Keywords: Cast-Designer, Metal Casting, Sprue System

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