Introduction............................................................................................................... 2 Filling system............................................................................................................. 2 Oxide Formation....................................................................................................... 3

Pouring Basin.........................................................................................................11 Tapered Sprue........................................................................................................12 Sprue Well.............................................................................................................12 Runner Bar and Gates............................................................................................14

Nomogram for Running System............................................................................16 Solidification Time Assessment............................................................................17 Gates......................................................................................................................18 Sprue Height..........................................................................................................19

Conclusion............................................................................................................... 21 Literature................................................................................................................. 22 List of Figures.......................................................................................................... 22

This lecture is concerned with filling the mould cavity with molten metal. Although this is one of the most important steps in producing a good quality casting, it is often the one which is the least understood and, as a result, it is often overlooked. It is all too common to see poor quality running systems in use in foundries, with consequential damaging effects on the quality of the castings produced.

\u2212 a small pouring basin
\u2212 a downsprue, which is divided into two smaller branches
\u2212 a sprue base or well
\u2212 horizontal runner bars which lead the molten metal towards the bottom of the

The feeding system, which is used to compensate for the shrinkage of the casting as it solidifies, is in two parts. One feeder can be seen on the top of the casting and another on the right hand side. It can be clearly seen that the filling and feeding systems are separate, which is appropriate since they perform completely different functions in the production of a casting. It should be noted that the filling and feeding systems can sometimes be combined (although it is usually much more difficult to design a combined system which accomplishes both functions equally well).

The difference between the very different functions of filling and feeding systems is emphasised when it is realised that, in the case of a typical casting, it might take ~ 10 seconds to fill the mould, whereas the feeding system would typically be operating for ~10 minutes as the casting solidifies. The present lecture will concentrate on the

In this example of an aluminium casting, it should be appreciated that the metal has been carefully introduced into the cavity through gates in the bottom of the casting. This is in contrast to many iron castings in which the metal is poured directly into the top of the casting cavity with very little thought being given to providing a proper filling system. In spite of this apparently rather crude approach to the filling of grey iron castings, they are nevertheless normally of quite a good quality. It is instructive to consider why this might be so.