CASTING DESIGN 2

1. Lower and Turbulent flow of molten metal:

One of the importance of casting design is to increase
laminar flow and decrease turbulent flow of molten
metal.
2. Reynold’s Number

If Re < 2,000 laminar flow

Re = 2000~4000 a little turbulent but not
harmful to casting.
Re > 4000 Turbulent flow
The flow of all fluids in ducts can be related to their Re.
3. For incompressible fluid,
Q = A1V1 = A2V2
NB: 1, 2 are positions at same level
4. Bernoulli’s equation:
If no frictional losses are involved, the sum of the P.E,
the K.E and the pressure energy for any point in the
same system is equal to that for any other point.
Pressure + K.E + P.E = const.
h + V12/2g + P1/ d = h + V22/2g + P2/d
Where, d= density of the liquidP= static pressure
p/d = pressure energy h=P.E
When pressure change is not too much, P1/d approx. O

ΔP.E + Δ K.E = const

h + v2/2g = const
g is constant v & √h
The optium height of pouring should be chosen so
that the v is not changed unnecessarily.

Usually h is chosen quite close to the sprue

V can be increased by increasing the height of flask.

 Gating Ratio
This is a factor to tell the mode of hot metal going
into the mold.
Defn: The ratio of cross sectional area of sprue:
total runners : total gates
pressurized system e.g 2:1.5:1
Gating ratio
unpressurized system e.g 1:2:2
 Gating Ratios
Sprue Runner Ingate
1. Cast Iron
for small & medium 2 1.5 1
for high 1 3 2
2. Steel & light metals
for small & medium 1 1 1
for high 1 2 1
3. Cu alloy
thin 4 3 2
thick 1 2 2
 Fluidity
Fluidity tester is needed to check the fluidity of metal before
pouring . We can decide the suited pouring temperature of the
metal by knowing its fluidity.
E.g. High manganese steel 1475oC (C= 0.92%Mn=11.5%)
If the pouring temperature is increased higher than this,
we shall obtain coarse grain growth and toughness will be
reduced.
NB: In the case of plain carbon steel, the properties of the casting can
be altered by heat treatment but for high Mn- steel , the properties
are fixed.
 Solidification
Grey cast iron expands in solidification because the

cementite decomposes, precipitating graphite.

Fe3C 3Fe + C

solid liquid

I vol. 4 vols.

Subsequently, if design and metal composition are

okay, there should be no shrinkage.

No riser needed for grey Fc if %C + 0.1(Si%) ≥3.5%

 Exothermic Sleeves ( or powder)
To delay the solidification of metal in the riser,
insulating sleeves are used or exothermic sleeves are
used(Exothermic powder can also be used).
For exothermic sleeves, they are formed from
exothermic powder into shapes like this
Thermit Reaction
2Al + Fe2O3 Al2O3 + 2Fe + Q

Exothermic Powder
Al Fe2O3 SiO2 Al2O3

20% 10% 25% 45%