Love Casting

This research was performed at Alloy Casting Industries in New Hamburg, Ontario Canada.
Tracking of velocity through an inline ceramic foam filter system.

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This simulation was performed at Alloy Casting Industries in New Hamburg, Ontario Canada. The casting is a 36 lb. carbon steel component being filled and fed by a 3″ diameter direct pour unit.

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Demolding my an address sign for the house, which I cast from aluminum using a simple investment casting technique. See my other video for the pour. The pattern is foam, which is vaporized by molten aluminum, which then fills the cavity.

I design plastic housings for a living and so constantly think about the part as it exists in a mold. A lot of effort goes into designing parts that are manufacturable and then chosing gating and mold constructoins that work.

Some of that experience has been proving useful in my DIY casting efforts, even though plastic injection tooling is a totally different world.

If there’s interest, I’ll keep posting videos of my metal casting experiments.

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Simulation of setup per Figure 6 from the paper entitled “A multiple-gate runner system for gravity casting”

I was curious to see the system in action; so modelled the exact geometry per figure 6. The paper was authored by:
Fu-Yuan Hsu, Mark R. Jolly, John Campbell

Ingate Velocity Graphs in order:
Scale:
Top: 3.5 m/s
Bottom: 0 m/s

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This simulation was performed at Alloy Casting Industries in New Hamburg, Ontario Canada.
An observation of thermal flow channel evolution during the delivery of molten metal to the mold cavity.

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A simulation comparing the assigned feeder parameters per Table 2. design 16 of the paper entitled “Tapered Riser Design Optimization” by Creese/ Xia

Plate casting moduls = 2 in. (plate thickness/2)
Plate casting volume = 1024 in3
Cylindrical feeder volume = 679 in3
Tapered feeder volume = 525 in3

The simulations were performed using an 18Cr-8Ni stainless steel in resin bonded sand molds.

I have run several simulations using the design parameters per table 2 (all with stainless steel) and have found that in all situations the tapered top feeder performed inadequately.

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As a matter of comparison; here is a modelled “textbook” AFS 1-4-4 fill system.
The temperature colour gradient =
Top:1600C
Bottom:1550C
Alloy: 1026 Carbon Steel

DO NOT USE THESE ANTIQUATED, ARBITRARY METAL DELIVERY SYSTEMS. THEY ARE INADEQUATE AND CANNOT PRODUCE WORLD-CLASS CASTINGS.

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The waterfall action of the metal entering each cavity is a nightmare and needs to be eliminated. You are certain to find that the first “dribbles” of metal entering the cavity will end up as an “inclusion” in the casting. In all situations it is important to prevent the metal from free-falling.

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The fill and feed system for this 30 lb. stainless steel casting was simulated at Alloy Casting Industries in New Hamburg, Ontario Canada. The window on the left shows the temperature profile during the pour. Top of the scale is 1600F, bottom of the scale is 1500F.

The window on the top right shows the liquid fraction – liquid metal in the mold.

The window on the bottom right shows shrinkage porosity.

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This simulation was performed at Alloy Casting Industries in New Hamburg, Ontario Canada. The casting is a 200 lb. alloy steel impeller.
For more information call Alloy Casting Industries at 519-662-3111 or visit us on the web at www.alloycasting.com

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