GCE 4145

Foundry Engineering
LECTURE 4: Gating

Mst. Esmotara Begum

Lecturer
GCE, RUET
Gating system
• The gating system is that part of the mold cavity through which the metal is poured to fill the
casting impression; its design is the principal means by which the foundryman can control the
pattern of metal flow within the mold.
• The series of funnels, pipes and channels used to guide liquid metal from the ladle into the
mold cavity is known as the gating system or the running system. Most of the damage is done
to castings by poor filling system design. So proper gating design is very important for quality
casting.
• Most castings are made by pouring the liquid metal into the opening of the running system
using the action of gravity to effect the filling action of the mold thus gravity sand casting and
gravity die-casting are important casting processes at the present time
• Gravity castings have, however, gained a poor reputation for reliability and quality, simply
because their running systems have in general been badly designed
surface turbulence had led to porosity and cracks, and unreliability in leak-tightness and
mechanical properties
Typical gating system

Typical gating system

Features of efficient gating systems
1. Economy of size
2. The filling of mold at the required speed for most castings, roughly equals
0.5 m/s
3. The delivery of only liquid metal into the mold cavity no other phases such
as slag, oxide, sand, air, or other gases
4. The elimination of surface turbulence
5. Establish proper temperature gradient
6. Reduction of air aspiration
7. High yield
8. ease of removal
Gating system types
Top pouring: When metal is poured through a top gate or directly into an open feeder head, the
stream impinges against the bottom of the mold cavity until a pool is formed. this is kept in a state
of agitation until the mold is filled. The erosive effect of the unconfined stream can be severe, whilst
the associated splashing gives an opportunity for oxidation. The principal advantages of top gating
are its simplicity for molding, its low consumption of additional metal, and, above all, the
generation of temperature gradients favorable to feeding from top heads; this arises from the
proportionately rapid cooling of the first metal poured, followed by the progressive accumulation of
metal from above until the mold is full.
Bottom Pouring: Quiet entry of metal into the mold cavity is best achieved by its introduction at the
lowest level. Using this method the metal rises steadily through the mold, splashing is eliminated
and dislodged molding material tends to be carried to the surface. Elimination of splashing and
mold erosion Less turbulence, less oxide formation. Unfavorable temperature gradient.
Side Pouring: Molding can be simplified by the discharge of metal into the side of the mold cavity
through ingates molded along a parting plane; this practice frequently offers the best compromise
between molding convenience and the ideal gating arrangement. Using side gating, progressive
mold filling can be achieved by tilting the mold towards the ingates to provide uphill casting
conditions.
Principles of Gating Design

Shape of fallen stream in down sprue

Schematic showing the advantages of a tapered sprue over a straight-sided sprue.
(a) Natural flow of free-falling liquid. (b) Air aspiration induced by liquid flow in a straight-sided
sprue. Also, the flow will tend to be uneven and turbulent (c) Liquid flow in a tapered sprue The
shape
Vortex
• causes turbulence that draws air, dross, or slag down into the sprue
• reduces the flow rate and causes disruption as it bursts at the free surface of metal rising in the
mold
• vortex can be minimized by reducing the velocity of metal and by increasing the liquid depth in the
pouring cup
The abrupt change in the flow channel cross-section
• Low-pressure zones - with a resulting tendency toward air entrainment (which is
also known as vena contracta - can be created as the metal stream pulls away
from the mold wall
• With a sudden reduction in the channel (Fig. a), the law of continuity shows that
the stream velocity must increase rapidly. This spurting flow will create a low-
pressure zone directly after the constriction
• With a sudden enlargement of the channel (Fig. b), momentum effects will carry
the stream forward and create low-pressure zones at the enlargement
• The problems illustrated in Fig. can be minimized by making gradual changes
in the flow channel cross-section; abrupt changes should be avoided
• Fig: Schematic showing the formation of low-pressure areas due to abrupt
changes in the cross-section of a flow channel. (a) Sudden reduction of the
channel. (b) Sudden enlargement of the channel
Abrupt change in the flow direction
• Fig.: Schematic illustrating fluid flow around right-angle and curved bends in a gating system. (a)
Turbulence results from a sharp corner. (b) Metal damage resulting from a sharp corner. (c) The
streamlined corner minimizes turbulence and metal damage
• Sudden changes in the direction of flow can produce low-pressure zones. Problems of air
entrainment can be minimized by making the change in direction more gradual
• If the velocity is high, mold gases and air and water from a moist atmosphere are aspirated or drawn
through the permeable mold into the flowing stream of metal