Elements of a Gating System:

Pouring Basin: This is where the molten metal employed to manufacture the part enters the mold. The pouring basin should have a projection with a radius around it to reduce turbulence. Down Sprue: From the pouring basin the molten metal for the casting travels through the down sprue. This should be tapered so its cross-section is reduced as it goes downward. Sprue Base: The down sprue ends at the sprue base. It is here that the casting's inner cavity begins. Ingate/Choke Area: Once at the sprue base the molten material must pass through the ingate in order to enter the inner area of the mold. The ingate is very important in flow regulation during the metal casting operation. Runners: Runners are passages that distribute the liquid metal to the different areas inside the mold. Main Cavity: The impression of the actual part to be cast is often referred to as the main cavity. Vents: Vents help to assist in the escape of gases that are expelled from the molten metal during the solidification phase of the metal casting process. Risers: Risers are reservoirs of molten material. They feed this material to sections of the mold to compensate for shrinkage as the casting solidifies. There are different classifications for risers. Top Risers: Risers that feed the metal casting from the top. Side Risers: Risers that feed the metal casting from the side. Blind Risers: Risers that are completely contained within the mold. Open Risers: Risers that are open at the top to the outside environment.

Figure:7

Advantages The metal casting process is extensively used in manufacturing because of its many advantages. 1. Molten material can flow into very small sections so that intricate shapes can be made by this process. As a result, many other operations, such as machining, forging, and welding, can be minimized or eliminated. 2. It is possible to cast practically any material that is ferrous or non non-ferrous. 3. As the metal can be placed exactly where it is requ required, ired, large saving in weight can be achieved. 4. The necessary tools required for casting molds are very simple and inexpensive. As a result, for production of a small lot, it is the ideal process. 5. There are certain parts made from metals and alloys that can only be processed this way. 6. Size and weight of the product is not a limitation for the casting process. Limitations 1. Dimensional accuracy and surface finish of the castings made by sand casting processes are a limitation to this technique. Many new casting processes have been developed which can take into consideration the aspects of dimensional accuracy and surface finish. Some of these processes are die casting process, investment casting process, vacuum vacuum-sealed sealed molding process, and shell molding olding process. 2. The metal casting process is a labor intensive process Functions of the Pattern 1. A pattern prepares a mold cavity for the purpose of making a casting. 2. A pattern may contain projections known as core prints if the casting requires a core and need to be made hollow. 3. Runner, gates, and risers used for feeding molten metal in the mold cavity may form a part of the pattern. 4. Patterns properly made and having finished and smooth surfaces reduce casting defects.

5. A properly constructed pattern minimizes the overall cost of the castings. Pattern should be= 1. Easily worked, shaped and joined 2. Light in weight 3. Strng, hard and durable 4. Resistant to wear and abrasion 5. Resistant to corrosion, and to chemical reactions 6. Dimensionally stable and unaffected by variations in temperature and humidity 7. Available at low cost The Metal Casting Operation Pouring of the Metal: When manufacturing by metal casting, pouring refers to the process by which the molten metal is delivered into the mold. It involves it's flow through the gating system and into the main cavity(casting itself). Factors of Pouring: Pouring Temperature: Pouring temperature refers to the initial temperature of the molten metal used for the casting as it is poured into the mold. This temperature will obviously be higher than the solidification temperature of the metal. The difference between the solidification temperature and the pouring temperature of the metal is called the superheat. pouring Rate: Volumetric rate in which the liquid metal is introduced into the mold. Pouring rate needs to be carefully controlled during the metal casting operation, since it has certain effects on the manufacture of the part. If the pouring rate it too fast then turbulence can result. If it is too slow the metal may begin to solidify before filling the mold. Turbulence: Turbulences is inconsistent and irregular variations in the speed and direction of flow throughout the liquid metal as it travels though the casting. The random impacts caused by turbulence, amplified by the high density of liquid metal can cause mold erosion. An undesirable effect in the manufacturing process of metal casting, mold erosion is the wearing away of the internal surface of the mold. It is particularly detrimental if it occurs in the main cavity, since this will change the shape of the casting itself. Turbulence is also bad because it can increase the formation of metal oxides which may become entrapped creating porosity in the solid casting.

Fluidity: Since pouring is a key element in the manufacturing process of metal casting, and the main goal of pouring is to get metal to flow into all regions of the mold before solidifying. The properties

of the melt in a casting process are very important. The ability of a particular casting melt to flow into a mold before freezing is crucial in the consideration of metal casting techniques. This ability is termed the liquid metals fluidity.

How to Increase Fluidity in Metal Casting: -Increase the superheat: If a melt is a higher temperature relative to its freezing point it will remain in the liquid state longer throughout the metal casting operation, and hence its fluidity will increase. However there are disadvantages to manufacturing a casting with an increased superheat. It will increase the melts likelihood to saturate gases, and the formation of oxides. It will also increase the molten metals ability to penetrate into the surface of the mold material. -Choose an eutectic alloy, or pure metal: When selecting a manufacturing material consider that metals that freeze at a constant temperature have a higher fluidity. Since most alloys freeze over a temperature range they will develop solid portions that will interfere with the flow of the still liquid portions as the freezing of the metal casting occurs. -Choose a metal with a higher heat of fusion: Heat of fusion is the amount of energy involved in the liquid-solid phase change. With a higher heat of fusion, the phase change, and hence the solidification of the metal casting will take longer and fluidity will be increased.

Shrinkage: Most materials are less dense in their liquid state than in their solid state, and more dense at lower temperatures in general. Due to this nature a metal casting undergoing solidification will tend to decrease in volume, during the manufacture of a part by casting this decrease in volume is termed shrinkage. Shrinkage of the casting metal occurs in three stages: 1. Decreased volume of the liquid as it goes from the pouring temperature to the freezing temperature. Figure:10

2. Decreased volume of the material due to solidification. Figure:11

3. Decreased volume of the material as it goes from freezing temperature to room temperature. Figure:12

Risers: When designing a setup for manufacturing a part by metal casting, risers are almost always employed. As the metal casting begins to experience shrinkage the mold will need additional material to compensate for the decrease in volume volume. . This can be accomplished by the employment of risers. Risers are an important component in the casting's gating system. Risers, (sometimes called feeders), serve to contain additional molten material. During the material's solidification process these reservoirs servoirs feed extra material into the casting as shrinkage is occurring, supplying it with an adequate amount of liquid metal. A successful riser will remain molten until after the metal casting solidifies. In order to reduce premature solidification of se sections ctions within the riser, in many manufacturing operations, the tops of open risers may be covered with an insulating compound, (such as a refractory ceramic), or an exothermic mixture, (such as iron oxide combined with powdered aluminum).

Figure:13

Porosity: One of the biggest problems caused by shrinkage, in the manufacture of a cast part, is porosity. It happens in at different sites within the material, when liquid metal can't reach sections of the metal casting where solidification is occurring. As the isolated liquid metal shrinks a porous or vacant region develops.

Development of these regions can be prevented during the manufacturing operation, by strategically planning the flow of the liquid metal into the casting through good mold design, and by the employment of directional solidification. These techniques will be covered in detail in theGating System and Mold Design section. Note that gases trapped within the molten metal can also be a cause of porosity. The effect of gases while manufacturing parts by metal casting will be discussed in the next section. Although proper casting methods can help mitigate the effects of shrinkage, remember some shrinkage, (like that which occurs in the cooling of the solid state to room temp.), can't be avoided. Therefore, the impression from which the metal casting is made is calculated oversized to the actual part, and the thermal expansion properties of the material used to manufacture the part will be necessary to include in the calculation.