ME 230:

ME 2202: PrimaryProduction
Primary Production Processes
Processes

CASTING
(Foundry)

Prof. S.K.Sahoo
 GATING SYSTEM
It refers to the passage way through which molten metal
passes to enter mould cavity.
It consists of :
1. Pouring cup or
basin
2. Sprue or
downsprue
3. Sprue base well
4. Skim bob
5. Runner
6. Runner extension
7. Gate or ingate
8. Riser
 Requirements of a good gating system
•It must introduce metal into the mold cavity with minimum turbulence.
•It should help to promote temperature gradient favorable for proper
directional solidification.
•It must prevent slag, dross or inclusions in ladle to reach the mold
cavity.
•It must avoid aspiration of air and mold gases in metal stream.
•The mold should completely filled in the optimum time, to avoid cold-
shut due to slow rise or erosion due to fast rise.
•It must not cause mold or core erosion.
•Ensures that enough molten metal reaches the mold cavity.
•Economical, practicable & easily to finish after casting.
•Maximize casting yield 
Actual mass of metal in mold cavity
Total mass of metal poured into mold
 •Pouring basin
•Act as a molten metal reservoir from
which it moves smoothly into the sprue.
•Prevent the slag to enter the mold cavity
by providing a skimmer or skim core.
•Molten metal in the pouring basin should
be full during the pouring operation, to
avoid aspiration effect i.e. a funnel shape
passage will from to drag air/slag into the
mold cavity.
•Sprue
•It controls the metal flow rate that enters into the runner &
gates to ultimately reach the mold cavity.
•Molten metal gains velocity when moves
downward, hence require small area of cross
section for same material to flow. If sprue cross
section is cylindrical throughout then low pressure
will be create at bottom & air will be sucked from
outside. Hence to make the sprue full i.e. to avoid
aspiration effect it should be made tapered.
•Strainer may be provider to trap slag, dross,
inclusions.
•Sprue base well
•Act as reservoir at the bottom of sprue to reduce momentum/
turbulence of molten metal to decrease the chance of erosion.
•Also it entraps the heavy solid impurities to settle at bottom.
•Shape of Sprue:
From Bernoulli's 1
P3 V32 P2 V22
  h2   hc
equation, w 2g w 2g 2
In limiting cases, P2  P3  0 V32 V22 Practical profile
  h2  (Straight taper)
2g 2 g ht h2
Ideal profile
•Applying continuity condition (parabolic)
between 2 and 3 , A2V2 = A3V3
3
A3  A3  h2 = Height of sprue
It gives, V2  V3 A  RV3 where,  R  A 

ht = Height of pouring basin
2  2 

V32 V 2 2 gh2
 h2  R 2 3  R 2
 1 
V 2 We have, V3  2 ght
2g 2g 3

2 gh2 h2 ht  h2 hc A3 hc
2
R  1  1   R 
2 ght ht ht ht It gives, A2 ht
• Square root suggest that profile of sprue should be parabolic in nature.
For easy maintenance and manufacturing, straight taper sprue is used.
 •Runner
•It is the channel generally located in the
horizontal plane (parting line) to distribute
metal from sprue to different regions of
casting by gates controlling rate of flow.
•It is trapezoidal in cross section, cut in the
cope side & gate in the drag half.
•It should run full so as to trap the slag, preventing them to flow into
cavity as slag (lighter in weight) are compelled to flow on the top of the
runner.
•Skim bob may be provided to trap slag on top & heavy particle at
bottom.
•Runner Extension
•Trap the impurities & reduce the momentum when there is a change in
flow direction.
•Gates / ingates
•These are the opening through which the molten metal entry into the
mould cavity.
•The shape & cross sectional should be such that it allows the molten
metal to enter the cavity without turbulence.
Type of gates / Ingates:
•Depending on the method & location of entry point to cavity. These are:
1. Top gating:
The molten metal is poured down through the
strainer & it enter direction or through riser to
the mold cavity at the top surface. Choke
Advantage:
•Quick filling, Sprue can act as riser
Mold cavity
•Favorable temperature gradient towards gate.
Disadvantage: Mold erosion due to turbulence & momentum.
2. Bottom gating:
Molten metal flows down to the bottom of the mold & enters
the cavity at bottom & rises gently in the mold. It uses a core
gate to flow the metal down to minimize heat loss.
Advantage:
•Avoid any mold erosion, less turbulence.
•Less gas / slag entrapment. Mold
Disadvantage: cavity
•Time to fill up more.
•Unfavorable temperature gradient & cold shut core gate
•Special sprue / core for location sprue in drag.
3. Horn gate:
It is another type of bottom gating when metal enters into
mold cavity through a horn gate at bottom producing a
fountain effect.
Advantage:
•It is a bottom gating without the necessity of a core for gate.
•Less turbulence.
Disadvantage:
•Unfavorable temperature gradient.
•Difficult to horn design.
 4. Parting line gating:
Metal enters the mold cavity along the parting line separating
the cope and drag. The sprue is connect to mold through a gate
in a horizontal direction. So there is possible to provide skim
bob or skim gate to trap slag.
Advantage:
• Skim bob can be given to trap slag
• Easy / economy to prepare.
Disadvantage:
• If the drag portion is deep,
it is likely to cause mold erosion.
 5. Side or step gating:
The metals enters at the side of the mold cavity, first near
the bottom and then progressively movers to the higher gates.
The size of the ingates are normally decreases from bottom to
top.
Advantage:
• Gradual filling without mold
erosion to produce a sound casting.
• Temperature gradient can be
maintained.
Disadvantage:
Most metal will try to enter
through the lowest gate.
 GATING RATIO
•It is Area ratio of Choke : Runner : Gate
Selection of gating ratio depend on;
•Characteristic of molten metal i.e., fluidity, slag formation tendency,
pouring temperature.
•Mold material Characteristic i.e., resistance to erosion, type of mold
sand etc.
• The base of the Sprue and Choke are the same.
• The ratios among cross-sectional area can be grouped into either
Pressurized or Unpressurized.
• Pressurized: A system where the gate and runner cross-sectional
areas are either equal or less than the choke cross-sectional area.
• Example: 1 : 0.75 : 0.66, 1:0.85:0.85 , 1:1:1 , 1:1:0.85
•Back pressure reduces aspiration as the sprue always runs full,
but leading to more turbulence and chances of mold erosion.
Unpressurized:
• The Runner must have a cross sectional
area greater than the Choke, and the
Gate(s) would equal or be larger than
the Runner(s). Example: 1 : 2 : 4 , 1 : 3 : 3
•Aspiration of gas occur as the system never runs full, but less
turbulence
Example:
For aluminum casting in green sand molding it is 1:2:4
For steel casting in dry-sand molding it is 1:2:1.5
For iron casting in dry-sand molding it is 1:4:4
 Simple Design Principle for Gating System
•The liquid metal flow from pouring basin to mold cavity through sprue,
runner & ingate. Simple calculation based on the principle of fluid flow
can be used to find out the different dimension & filling time.
•Bernoulli theorem: The total energy head remain constant at any
section of fluid flow, P.ie,E.(Head) + Press.+ Kinetic E. + Fric. =constant
w= specific weight of liquid
Mathematically, P1 V12 P2 V22
h1    F1  h2    F2 g=acc. due to gravity
w 2g w 2g F=friction head
V=velocity
•Law of continuity: Volume of metal flow at any h=potential head
section in the mold is constant. (Volumetric flow rate) *
1
sprue
Q  V1 A1  V2 A2
Where, Q = rate of flow m3/s
A = area of CS, m2
V = velocity, m/s
mold 2
It may not be applicable as metal flow with heat loss & heavy *
friction loss.
 Mold filling time (MFT)
MFT = Mold filling time (sec)
Vc V c = Volume of mold cavity (m3)
MFT 
Q Q = Volumetric flow rate
1
1. Top gating system:
Applying Bernoulli’s equation:
h
P1  P2  0 (Atmospheric pressure) F1  F2  0 (Neglected) Choke
V1  0 h2  0 Base (Datum) point When h2=0 ⇒ h1=h 2
Speed at the Choke: V22 Top gating
h1   V2  2 gh
2g
A2=A = Area of cross section of gate/choke
Vc Vc Vc
MFTTop gating   
Q A2V2 A 2 gh
 2. Bottom gating system: 1

Applying Bernoulli’s equation between 1 &2:

P2 V22 H mold 3
H  2 h Hm
w 2g
Applying Bernoulli’s equation between 2 &3 inside the mold
P2 Just after entry point, in the mold all kinetic energy is lost
h
w A = Area of cross section of gate
It gives, h =height of metal in he mold at a particular time ‘t’
2
V2 Am= Area of cross section of mold
H  h
2 g  V2  2 g ( H  h)
Let in time ‘dt’ metal height in the mold move by an amount ‘dh’
Applying continuity equation Am  dh  A  V2
dt
Am dh Am dh
 dt    
A V2 A 2 g ( H  h)
 T = Total time to fill the mold height Hm T Hm
Am dh
 dt  
0 0
A

2 g ( H  h)

 T  MFTbottom gating 
Am
A

2
g
  H  (H  H m ) 
Example:
Mold of 50 X 25 X 15 cm is filled by a top gating system with cross-
section area of gate is 5cm2 . Find mold filling time.
Answer:
As per Bernoulli equation, Velocity at choke/throat  2 gh
 2  98115  171.6 cm / sec
Volume of mold, V =50X25X15 cm2
Volume of casting 50  25  15
Filling time    21.86 sec
velocity  gate area 5  171.6
Example:
A mold 60 × 30 × 16 cm is to be filled by liquid metal in sand casting
process. Determine the time taken to fill up the mold when area of gate is
6.0 cm2 & height of gate from top of pouring basin is 16 cm.
Answer:
(a) Top gating, (b) Bottom gating system.

16
H=16
30
30
16
60
60 Bottom gating
Top gating

•Top gating:
Vmold = 60 × 30 × 16 = 28800cm2
Vg = Velocity at gate  2 gh  2  98116  177.2 cm / sec
 Volume of mold cavity 28800
T   27 sec
v g  Ag 6  177.2

•Bottom gate:
Am = 60 × 30 = 1800
Ag = 6, H = 16, Hm = 16 = Height of mold.

Tbottom gating 
Am
Ag

2
g
  H  (H  H m ) 


1800
6

2
981

 16  (16  16) 
= 54.2 sec.
 Example: The downsprue leading into the runner of a certain mold
has a length = 175 mm. The cross-sectional area at the base of the
sprue is 400 mm2. The mold cavity has a volume = 0.001 m3.
Determine: (a) the velocity of the molten metal flowing through the
base of the downsprue, (b) the volumetric flow rate, and (c) the time
required to fill the mold cavity.
Solution:
(a) Velocity v = (2gh)0.5 = (2 x 9810 x 175)0.5= 1853 mm/s
(b) Volume flow rate Q = vxA= 1853 x 400 = 741,200 mm3/s
(c) Time to fill cavity MFT = V/Q =106/741,200=1.35s
 Riser or Feeder
Function:
Risers are reservoirs of liquid metal that feed extra metal to
the mold to compensate for volumetric shrinkage of the
casting over the total solidification period
Requirements:
•Thermally adequate i.e., metal in the riser
should solidify in the end.
•Volumetrically adequate; i.e., sufficient for
compensation the shrinkage in the casting.
•Adequate feeding range, i.e., riser should cover the entire
casting to eliminate center line shrinkage, promote directional
solidification. Two or more riser can be provided.
 Types
•Top riser (open)
•Side riser (open)
•Blind risers ( Can be top or side)
•Top risers are most common & also most efficient,
provided on casting where hot spots are accessible
from top directly. Act efficiently by gravitational
force and also help to exhaust mold gases.
•Where hot spots are not accessible directly from
top side risers are provided.
•Blind risers are used to feed localized hot spots
which are not accessible to top & side risers. These
riser remain inside of mold. It reduced the
requirement of feed metal, otherwise need excessive
height of open risers. William or wash burn core is
used to connect it to atmosphere.
 Solidification Process
• Solidification occurs in two stages
– Nucleation
– Growth
• It is influenced by
– Material
– Cooling rate
– Pouring temperature (amount of super heat)
– Design and location of riser
• Most of the metallurgical defects occur
because of improper solidification design
 Nucleation
• It is the formation of the new stable solid particle from the
liquid metal when there is a net release of energy from the
liquid
• Nucleation generates surface which required energy. As a
result, nucleation occurs at a temperature below
equilibrium melting temperature.
• The difference between the melting point and the
temperature at which nucleation occurs is called
undercooling
• In most situations, nucleation starts from mold walls, ie,
relatively cold surface.
• Some time solid particles (impurities) are added
deliberately for uniform solidification within the molten
liquid. It is called inoculation, it promotes nucleation.
 Grain Growth
• Grain growth occurs as the heat of fusion is continuously extracted
from the liquid
• Direction of growth, rate, and type of growth can be controlled by
– The way in which fusion heat from liquid is removed
– Control rates of nucleation and growth for the size and shape of
the crystals
– Faster cooling rates generally produce finer grain sizes (better
mechanical properties)
• Directional instead of progressive solidification, in which molten
metal get solidify and its shrinkage compensated continually is most
required for production of a soud casting.
• when cooling rate is stable columnar crystal growth occur
• For alloy metals because of irregular temperature gradient ahead of
solid surface, dendritic crystal growth occur.
 Directional vs. Progressive solidification
Directional solidification
•Desirable
Source of
molten metal
Progressive solidification
•Unwanted

Combination of progressive and

directional solidifications Arrow indicate solid front
movement direction
Flow of molten
metal
•Directional movement should
be more than progressive to
avoid porosity
 Cooling Curves for a Pure Metal
• Cooling rate is the slope of the
cooling curve
• Pure metals have distinct freezing
temperature after thermal arrest
to remove latent heat. distinct
freezing/ solidification point
•More pouring temperature means
more super heat means the metal
has more time to flow into the
intricate area but more time to cool

•Under cooling is required to induce the initial nucleation, the

subsequent solidification may relished enough heat to increase in
temperature back to the melting point. This increase in temperature,
know as recalescence.
•The solidification time, ts = Time from pouring to the completion
solidification
 Grain structure in a casting of a pure metal
•Randomly oriented grains of small size
near the mold wall (chill zone)
•Large columnar grains oriented toward
the center of the casting

• Rapid cooling produces equiaxed

(roughly round) small grains enhance
good mechanical properties.
• Slow cooling towards the interior
forms long columnar grains that grow
towards the center
 Cooling Curves for an Alloy
• For alloy Solidification occur over a freezing range of temperatures
• Beginning and end of solidification are indicated by changes in slope

•The specific form of a cooling curve depends on the type of

material being poured, the nature of the nucleation process, rate &
means of heat removal from the mould.
•The solidification time, ts = Time from pouring to the completion
solidification
 Grain structure in a casting of an alloy metal
•Segregation of alloying components
in center of casting
•Cast grain structure obtained
by using nucleating agent

A nucleating agent
(inoculant) is a substance
that induces grains to
nucleate and form at the
same time throughout
the structure.
 Grain Growth in Metal Solidification
•For pure metal and when cooling rate is stable
columnar crystal growth occur.
•For alloy metals and because of irregular
temperature gradient ahead of solid surface,
dendritic crystal growth occur.
Dendrites:
•Tree-like structures that form during the solidification of alloys.
•Slow cooling rates produce dendrites with larger branch spacing; faster
cooling rates produce finer spacing; very fast cooling rates produce no
dendrites

Columnar Equiaxed Equiaxed non-dendendrites

 Cast Structure
• Three distinct regions or zones
– Chill zone
• Rapid nucleation occurs when the molten
metal comes into contact with the cold walls
of the mold
• Forms a narrow band of randomly oriented
crystals on the surface of a casting
– Columnar zone (least desirable)
• Rapid growth perpendicular to the casting
surface
• Long and thin
• Highly directional
– Equiaxed zone
• Crystals in the interior of the casting
• Spherical, randomly oriented crystals
 Prediction of Solidification Time: Chvorinov’s Rule
• Total solidification time TST = time required for casting to
solidify after pouring
• TST depends on size (volume) and shape (surface area) of
casting by relationship known as Chvorinov's Rule
n
V  where,
TST  K  
 A V = volume of the casting;
A = surface area of casting;
n = cooling exponent (1.5-2.0) typical
value = 2 for metal
K = mold constant.
• K depends on mold material, thermal properties of casting
metal, and pouring temperature relative to melting point.
It is obtained by experimentation.
 Mold
• A casting with Constant in ratio
a higher (V/A) Chvorinov's Rule
cools and solidifies
more slowly than one with a lower ratio
– To feed molten metal to mold cavity, TST for riser must
be greater than TST for mold casting [TSTriser>TSTcasting]
• Since riser and casting mold constants will be equal, riser is
designed to have a larger (V/A) ratio so that the casting
solidifies first
─ It ensure that last particle of liquid in mold when solidify
is supplied with liquid metal from riser.
– This minimizes the effects of Solidification shrinkage
•The riser is generally assume to take 25% longer time than
casting to solidify.
 Solidification Shrinkage
• Most metals undergo
noticeable volumetric
contraction when cooled
• Three principle stages of
shrinkage:
– Shrinkage of superheat
liquid as it cools from
pouring temperature
─Solidification shrinkage as the liquid turns into solid
─Solid metal contraction as the solidified metal cools
to room temperature
 Example

starting level of molten reduction in level caused

reduction in height and
metal immediately by liquid contraction
formation of shrinkage cavity
after pouring during cooling (if riser is
caused by solidification
not used)
shrinkage (if riser is not used)

further reduction in height and

diameter due to thermal contraction
during cooling of the solid metal (if
riser and pattern allowance is not
used)
 Riser Design and Solidification Shrinkage
• Amount of liquid metal contraction depends on the coefficient of
thermal contraction and the amount of superheat
• Cavities and voids can be prevented by designing the casting to have
directional solidification
• Hot tears can occur when there is significant tensile stress on the
surface of the casting material because of shrinkage
• Located so that directional solidification occurs from the farthest
point of the mold toward the riser
• Should feed directly to the thickest regions of the casting
• Casting Yield: the weight of the casting divided by the weight of
metal in the pour (i.e. the casting, gating systems, and all associated
risers) should be maximum
• A good shape for a riser is one that has a longer freezing time.
 Solidification Aids
• Solidification of the casting can be enhanced by providing chills at
required locations.
• Pieces of material placed in the mold to speed up heat transfer in
thicker areas of the part to prevent shrinkage porosity
External chills
Masses of high-heat capacity material placed in the mold
Absorb heat and accelerate cooling in specific regions

Internal chills
Pieces of metal that are placed
in the mold cavity and promote
rapid solidification
Ultimately diffused and become
part of the cast part
Example:
Find the diameter of the riser to be used for a casting of 200 X 100 X 18
mm rectangular plate. Assume height of riser equals to that of diameter.
Riser takes 25% longer time to solidify
Answer:

here, mold constant K, for both assumed same.

 CLEANING OF CASTINGS
The complete processes of the cleaning of castings, called
fettling. It involves removal of :
•Adhering sand
•Gates
•Risers
•Chipping out any unnecessary project from surface.
Various cleaning processes are:
•Rough cleaning: Involves cleaning of gates & risers.
–If casting is of brittle material the projects can be Broken off
by impact force given by a rod or hummer.
–For ductile material it can be done by band saw or hacksaw
or abrasive cut of wheel or shearing machine.
–If riser or spur are very large then oxygen cutting flame can
be used.
–If casting is large & oxidation resistant, then powder cutting
is employed (a stream of iron powder is introduced into the
oxygen torch flame)
•Surface cleaning: It Include interior and exterior cleaning of
sand, scale & other adhering materials. It is done by
–Tumbling: casting are kept in a barred
barrel
that is completely closed and rotated in
a horizontal axis 30-40 rpm. It can be
assisted with grit, steel/ cast balls,
compressed air, caustic soda water etc.
for cleaning.
–Blasting: Castings are kept in a closed box &
abrasive grits are thrown at high speed by
speed by compressed air.
–Others surface cleaning processes: Wire
Brushing, buffering, chemical pickling,
polishing, painting, etc.
•Trimming: It is done before after or during initial
surface cleaning. It is removal of fins or other
protruding surface from casting like: Fins
protrusion at chaplets, wires, parting liner etc.
•Procedures are:
–Chipping: By chisel & hummer, manually or by pneumatic. It
is used to remove fins, gate & riser pads, wires, cores etc.
–Grindings: Hand grinders or pedestal grinder.
–Finishing: Cleaning completed after trimming, if more
finishing required, than casting may go for.
–Machining, etc.
•Removing the Core
–Knocking out of dry sand cores a iron bar.
–For quick knocking pneumatic or hydraulic
devices are employed, this method is used
for small, medium work. For large castings
the hydro blast process is mostly employed.
 CASTING DEFECTS
The defect in a casting may arise due to the defect/improper
handling/design in one or more of the followings:
•Design of casting & pattern
•Molding sand and design of mold & core
•Metal composition
•Melting & pouring
•Gating & risering
The most commonly defect encountered in sand casting can
be classified into 7 categories.
1. Metallic projections 2. Cavities
3. Incomplete casting 4. Incorrect dimensions/shape
5. Discontinuities 6. Inclusions
7. Defective surface
1.Metallic projections:
Penetration :When fluidity of liquid metal is high, it may
penetrate into sand mold or sand core, causing casting
surface to consist of a mixture of sand grains and metal
Fins are excessive amounts of metal created by solidification into
the parting line of the mold.
Swells are excessive amounts of metal in the vicinity of gates or
beneath the sprue
Scabs are surface slivers caused by splashing and rapid
solidification of the metal when it is first poured and strikes the
mold wall
Wash are projected part at gate
 2.Cavities
•Shrinkage cavities are cavities that have a
rougher shape and sometimes penetrate
deep into the casting.
•Shrinkage cavities are caused by lack of
proper feeding or non-progressive
solidification or improper riser

Hot spot

Stress
concentration at
Cavity
cavity may cause
failure
 Porosity: caused by shrinkage or trapped gases, or both
Types: A. Solidification defects
B. Trapped gases
C. Residual air
Microporosity: too rapid solidification
seen as small irregular voids, dendritic
shrinkage during solidification
Pin hole porosity-tiny spherical voids, cause
due to release of entrapped gases while
solidification

Blowholes formed by gas entrapped

during solidification
3.Discontinuities
Due to : 1. Improper fusion of different streams of metals
2.Improper solidification can cause hot tears
A hot crack is a crack formed during cooling after solidification
because of internal stresses developed in the casting

Hot tears are casting defects caused by tensile stresses as

a result of restraining a part of the casting. Usually created
at hot spot (more metal accumulation areas, sharp change
of dimension, etc)
Cold Shut: Two streams of metal flow together but
there is a lack of fusion due to premature freezing

Cold cracks: fine long cracks, occurs to residual stress after

solidification in brittle casting.
 4. Defective surface
Casting surface irregularities that are caused by incipient freezing from
too low a casting temperature
•Blow: It is a fairly large, well rounded cavity produced
by gases, which displace the molten metal. Due to
poor venting, high gas evolving.
Blister: It is a scar covered by the thin layers of the
metal
Scar: A shallow blow on flat casting
Scab: It is a rough irregular project on surface
with a fold containing a layer of sand under it. It is
due to the high thermal expansion of tightly
rammed sand.
 Sand Blow: Balloon-shaped gas cavity caused
by release of mold gases during pouring

•Sand fusion/ burn on: Due to the high pouring

temperature the sand or clay fuse & attach with
the surface of castings. It gives a brittle & glossy
look to the surface.

Sand adhering: Attachment of sand on the surface

Depression: A shallow surface on flat casting

Wrinkles: Wavy surfaces

5.Incomplete casting
Misrun: A casting that has solidified before completely
filling mold cavity
Due to :
1.Premature solidifications (low pouring temperature)
2. Insufficient metal poured,
3. Leaks in the mold
6.Incorrect dimensions ,incorrect
allowances, deformed pattern,
pattern mounting error
7.Inclusions
-Materials from alloys, crucible ,mold etc, sand particles,
ceramic particles, Can be avoided using filters, good strong
molds etc.
– Unfused internal chills/chaplets: Non-homogenity on surface or
internal, improper design of chill & plates.
Cold Shot : Metal splatters during pouring and solid
globules form and become entrapped in casting
 Cause-effect /Fish-bone Diagram
It is the diagrammatic representation of final effect and its all major
and its subsidiary causes
Casting Design Material characteristics Melting
Course High pouring temp
Sharp Improper
junctions sand size
corners Gas absorption
More temp. gap during pouring
Sudden change Having large of solidification
in dimensions shrinkage of alloy metal Hot Tear/
cracks
Poor collapsibility No directional
of sand, core solidification

Not providing Improper riser

Excessive hard location and size
chills core, mold

Molding Sand, Cores Gating and Risering

 Design Considerations in Casting
•Avoid hot spot formation due to sharp corner, abrupt cross
section change, as they cause hot tearing, crack, shrinkage cavity
•Provide adequate fillet, uniformity in cross section, chills etc.

Hot spot

Poor Good Better

Try to avoid using core by
incorporating design change
Design uniform wall thickness: Ensure uniform cooling and avoid
hot spot, shrinkage, porosity, or cracking
INCORRECT CORRECT

Uniform wall
thickness
Non-uniform
wall thickness
Corners : Round corners (Fillet) to reduce stress concentrations
and fracture
•Inner radius should be at least the thickness of the walls
INCORRECT CORRECT

Sharp corner Rounded corner

For pulleys and wheels spokes are curved to compensate
the tensile stress and of odd number

Poor Good Better

Sufficient draft
should be provided
in pattern
Proper design of parting line is required : flattest
parting line is best
It is recommended to avoid small projection. It may be made
separate and attach it to the large casting by an appropriate
joining method.

Avoid thin wall of casting, Recommended wall thicknesses are:

Gray-iron & aluminum : 4.0 mm minimum
Malleable iron & steel : 4.5 mm minimum
Bronze, brass, magnesium: 2.5 mm minimum
Abrupt change in section should
be avoided

Poor Good
Staggered ribs to be used to prevent cracking during cooling

Risers should be attached to the

heaviest section

Poor Good