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The gating and riser system (feeder) design play very important role for improving casting quality. Many defects such as tensile void, porosity and segregation in products produced by casting methods may be detected. The porosity is the one of the defects most frequently encountered in casting. Porosity formation cause costly scrap loss and limits the use of cast parts in applications requiring high sealing. The amount of porosity is closely related to sand casting process parameters. A considerable reduction in porosity formation can be obtained using riser design optimization technique in the sand casting process. The design of feeder requires knowledge and experience. Therefore, hot spot formation, solidification period, feeder sprue and volume are important criteria. However, these may be not enough to produce high quality castings, and the importance of simulation techniques increases. The aim of this study is to make a feeder design optimisation for a cast part produced from Etial 160 aluminium alloy by sand mould casting method. In this study, gating and riser design, module criteria, feeder volume and size were investigated by SOLIDCast casting simulation program. The real and simulated casting values were compared with each other in the light of macro and micro-porosity results.
International Iron & Steel Symposium
UDCS
Mustafa ERCAN
Erdal Karadeniz
Murat ÇOLAK