Effect of Gating Sprue Height on Mechanical Properties of Thin Wall Ductile Iron
Effect of sprue/metal head height on mould filling,
microstructure and mechanical properties of TWDI casting is studied.
Results show that metal/sprue height of 50 mm is not sufficient to
push the melt through the gating channel, but as it is increased from
100-350 mm, proper mould filling is achieved. However at higher
heights between 200 mm and 350 mm, defects associated with
incomplete solidification, carbide precipitation and turbulent flow are
evident. This research shows that superior UTS, hardness, nodularity
and nodule count are obtained at 100 mm sprue height.
[1] Stefanescu, D. M. Ruxanda, R., Dix, L. P. “The Metallurgy and Tensile
Mechanical properties of Thin Wall Spheroidal Graphite Iron”.
International Journal of cast Metals Research 16(1-3), 2003, Pp. 319-
324.
[2] Fras E and Gorny M: “Structure of Thin Wall Austempered Ductile Iron
(TWADI)”, Proceedings of the 8th International Symposium on Science
and Processing of Cast Iron, Beijing- China, Oct. 16-19 (2006), p. 157.
[3] Lee, P.D, Chirazi, A and See, D. “Modelling Micro-Porosity in
Aluminium-Silicon Alloys: A Review. Journal of light metals. Vol.1,
2001 Pp 15-30.
[4] Katzarov, I.H. “Finite Element Modelling of the Porosity Formation in
Casting. International Journal of Heat and Mass Transfer. Vol 46, 2003
Pp. 1545-1552.
[5] Manjunath Swamy H. M, Nataraj, J. R, Prasad, C. S “Design
Optimization of Gating System by Fluid Flow and Solidification
Simulation for Front Axle Housing” International Journal of
Engineering Research and Development. Vol.4, Issue 6. 2012, Pp 83-88
[6] Hassan Jafari, Mohd Hasbullah Idris, Ali Qurdjini, Majid Karimian,
Gholam Hassan Pyganeh. “Influence of Gating System, Sand Grain
Size, and Mould Coating on Microstructure and Mechanical property of
Thin Wall Ductile Iron” Journal of Iron and Steel Research,
International, 2010. 17(12) Pp 38-45
[7] Lubos Pavlak, "Effect of Filling Conditions on the Quality of Cast
Aluminium Cylinder Heads", Metalurgija: Journal of Metallurgy, Vol-
14, br. 1, str. 2008. Pp 31-39
[8] Mohd Rizuan Mohammed Shafiee. “Effect of Gating Design on the
Mechanical Strength of Thin Section Casting.” Elsevier: Journal of
Material Processing Technology, Vol.105, 2009, pp 128-133.
[9] Hu, B.H., Tong, K.K., Niu, X.P and Pinwill, I. “Design and optimization
of runner and gating system for the die casting of thin walled
magnesium telecommunication parts through numerical simulation.”
Journal of Materials Processing Technology, Volume 105, 2002, pp 128-
133.
[10] Dai, X., Yang, X., Campbell, J and Wood, J. “Effects of runner system
design on the mechanical strength of Al-7Si-Mg alloy castings” Journal
of Material Science and Eng, A354, 2003, pp 315-325.
[11] Ahmad, R and Hashim, M. Y. “Effect of vortex runner gating system on
the mechanical strength of Al-12Si alloy castings” Archives of
Metallurgy and Materials. Volume 56, Issue 4. 2011, pp 991-997.
[12] B Naveenkumar and Bharat.S.Kodli. “Design optimization of gating
system by fluid flow and solidification simulation for pump casing by
sand casting” International Journal of research in Engineering and
Advanced Tech. Vol.2, Issue 4. ISSN: 2320-8971. 2014, pp 1-5
[13] Mohd Yussni Hashim, Azriszul Mohd Amin and Vijay R. Raghavan.
2007 “Effect of Runner Diameter on the mechanical strength and
porosity distribution of thin section casting” Proceeding of Regional
Conference on Engineering Mathematics, Mechanics, Manufacturing
and Architecture. 2007, pp 175-182
[14] Naveen Hebsur and Sunil Mangshetty, 2014 “Casting simulation for
sand casting of Flywheel” Int. Journal of Research in Advent
Technology. Vol. 2, No. 8, E-ISSN: 2321-9637. 2014, pp 82-86
[15] E Manjunath Swamy H. M “Design optimization of gating system by
fluid flow and solidification simulation for front axle housing”
International Journal of Engineering Research and Development. Vol. 4,
2012, pp 83-88
[16] Attar, E., Homayonifar, P., Babaei, R., Asgari, K. and Davami, P.
“Modeling of air pressure effects in casting moulds” Journal of
Modeling and Simulation in Material Science and Eng. Vol. 13, 2005,
pp 903-917
[17] Voigt, Robert. C, “Fillability of Thin Wall Steel Castings” (Undated)
The Pennsylvania State University, 2002.
[18] Capadona, J. A and Albright, D. L. ” Review of Fluidity testing as
Applied to lost- Polystyrene Investment Casting” Transactions,
American Foundrymen’s Society, 86. 1978, pp 43-54.
[19] M. Gorny, “ Temperature drop in liquid iron in thin wall channels during
mould filling” Archieves of Foundry Eng. ISSN (1897-3310) Vol. 9
Issue 1, 2009, pp 137-142
[20] Mazhar Igbal, “Gating Design Criteria for Sound Casting” International
Journal of Mechanical Engineering and Robotics Research. ISSN 2278-
0149. Vol. 2, No.3, 2014, pp 675-694.
[21] M. Masoumi, H. Hu, J. Fedjazi, M. A Boutorabi. 2005 “ Effect of Gating
Design on Mould filling”, American Foundry Society Transactions, 113,
2005, pp 185-196
[1] Stefanescu, D. M. Ruxanda, R., Dix, L. P. “The Metallurgy and Tensile
Mechanical properties of Thin Wall Spheroidal Graphite Iron”.
International Journal of cast Metals Research 16(1-3), 2003, Pp. 319-
324.
[2] Fras E and Gorny M: “Structure of Thin Wall Austempered Ductile Iron
(TWADI)”, Proceedings of the 8th International Symposium on Science
and Processing of Cast Iron, Beijing- China, Oct. 16-19 (2006), p. 157.
[3] Lee, P.D, Chirazi, A and See, D. “Modelling Micro-Porosity in
Aluminium-Silicon Alloys: A Review. Journal of light metals. Vol.1,
2001 Pp 15-30.
[4] Katzarov, I.H. “Finite Element Modelling of the Porosity Formation in
Casting. International Journal of Heat and Mass Transfer. Vol 46, 2003
Pp. 1545-1552.
[5] Manjunath Swamy H. M, Nataraj, J. R, Prasad, C. S “Design
Optimization of Gating System by Fluid Flow and Solidification
Simulation for Front Axle Housing” International Journal of
Engineering Research and Development. Vol.4, Issue 6. 2012, Pp 83-88
[6] Hassan Jafari, Mohd Hasbullah Idris, Ali Qurdjini, Majid Karimian,
Gholam Hassan Pyganeh. “Influence of Gating System, Sand Grain
Size, and Mould Coating on Microstructure and Mechanical property of
Thin Wall Ductile Iron” Journal of Iron and Steel Research,
International, 2010. 17(12) Pp 38-45
[7] Lubos Pavlak, "Effect of Filling Conditions on the Quality of Cast
Aluminium Cylinder Heads", Metalurgija: Journal of Metallurgy, Vol-
14, br. 1, str. 2008. Pp 31-39
[8] Mohd Rizuan Mohammed Shafiee. “Effect of Gating Design on the
Mechanical Strength of Thin Section Casting.” Elsevier: Journal of
Material Processing Technology, Vol.105, 2009, pp 128-133.
[9] Hu, B.H., Tong, K.K., Niu, X.P and Pinwill, I. “Design and optimization
of runner and gating system for the die casting of thin walled
magnesium telecommunication parts through numerical simulation.”
Journal of Materials Processing Technology, Volume 105, 2002, pp 128-
133.
[10] Dai, X., Yang, X., Campbell, J and Wood, J. “Effects of runner system
design on the mechanical strength of Al-7Si-Mg alloy castings” Journal
of Material Science and Eng, A354, 2003, pp 315-325.
[11] Ahmad, R and Hashim, M. Y. “Effect of vortex runner gating system on
the mechanical strength of Al-12Si alloy castings” Archives of
Metallurgy and Materials. Volume 56, Issue 4. 2011, pp 991-997.
[12] B Naveenkumar and Bharat.S.Kodli. “Design optimization of gating
system by fluid flow and solidification simulation for pump casing by
sand casting” International Journal of research in Engineering and
Advanced Tech. Vol.2, Issue 4. ISSN: 2320-8971. 2014, pp 1-5
[13] Mohd Yussni Hashim, Azriszul Mohd Amin and Vijay R. Raghavan.
2007 “Effect of Runner Diameter on the mechanical strength and
porosity distribution of thin section casting” Proceeding of Regional
Conference on Engineering Mathematics, Mechanics, Manufacturing
and Architecture. 2007, pp 175-182
[14] Naveen Hebsur and Sunil Mangshetty, 2014 “Casting simulation for
sand casting of Flywheel” Int. Journal of Research in Advent
Technology. Vol. 2, No. 8, E-ISSN: 2321-9637. 2014, pp 82-86
[15] E Manjunath Swamy H. M “Design optimization of gating system by
fluid flow and solidification simulation for front axle housing”
International Journal of Engineering Research and Development. Vol. 4,
2012, pp 83-88
[16] Attar, E., Homayonifar, P., Babaei, R., Asgari, K. and Davami, P.
“Modeling of air pressure effects in casting moulds” Journal of
Modeling and Simulation in Material Science and Eng. Vol. 13, 2005,
pp 903-917
[17] Voigt, Robert. C, “Fillability of Thin Wall Steel Castings” (Undated)
The Pennsylvania State University, 2002.
[18] Capadona, J. A and Albright, D. L. ” Review of Fluidity testing as
Applied to lost- Polystyrene Investment Casting” Transactions,
American Foundrymen’s Society, 86. 1978, pp 43-54.
[19] M. Gorny, “ Temperature drop in liquid iron in thin wall channels during
mould filling” Archieves of Foundry Eng. ISSN (1897-3310) Vol. 9
Issue 1, 2009, pp 137-142
[20] Mazhar Igbal, “Gating Design Criteria for Sound Casting” International
Journal of Mechanical Engineering and Robotics Research. ISSN 2278-
0149. Vol. 2, No.3, 2014, pp 675-694.
[21] M. Masoumi, H. Hu, J. Fedjazi, M. A Boutorabi. 2005 “ Effect of Gating
Design on Mould filling”, American Foundry Society Transactions, 113,
2005, pp 185-196
@article{"International Journal of Chemical, Materials and Biomolecular Sciences:70457", author = "E. F. Ochulor and S. O. Adeosun and S. A. Balogun", title = "Effect of Gating Sprue Height on Mechanical Properties of Thin Wall Ductile Iron", abstract = "Effect of sprue/metal head height on mould filling,
microstructure and mechanical properties of TWDI casting is studied.
Results show that metal/sprue height of 50 mm is not sufficient to
push the melt through the gating channel, but as it is increased from
100-350 mm, proper mould filling is achieved. However at higher
heights between 200 mm and 350 mm, defects associated with
incomplete solidification, carbide precipitation and turbulent flow are
evident. This research shows that superior UTS, hardness, nodularity
and nodule count are obtained at 100 mm sprue height.", keywords = "Melt pressure and velocity, nodularity, nodule count,
sprue height.", volume = "9", number = "2", pages = "360-8", }
