Effect of Cooling Rates

❖ Slow cooling rate (on the order of 102 K/s) long local

solidification time Coarse dentric structure with large

spacing between the dentric.

❖ Faster cooling rates (on the order 104 K/s) short local
solidification time the structure becomes finer with
small dentric arm spacing.
❖ Higher cooling rates (on the order of 106 to 108 K/s) the
structures developed are amorphous.

Fluid Flow
The basic casting system as shown below
Fig. 10.7 schematic illustration of typical riser gated casting
Sprue: is a vertical channel through which the molten metal flows
downward in the mold.

Runner: are the channels that carry the molten metal from sprue to the
mold cavity, or connect the sprue to the gate.

Risers: serve as reservoirs to supply the molten metal necessary to

prevent shrinkage during solidification.

Fig. Casting fed by (a) a top riser, and (b) a side riser

Gate: Is that portion of the runner through which the molten metal
enters the mold cavity.

Fig. Multiple gating system in sand casting

Function of gating system in sand casting as following:

1. Trap contaminants (such as oxides and other inclusion) in the

molten metal
2. Avoids or minimizes problems (such as premature cooling,
turbulence and gas entrapment).

Bernoulli's Theorem

This theorem is based on the principle of conservation of energy

𝑝 𝑣2
ℎ+ + = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 …………………………………10.2
𝜌𝑔 2𝑔

Where

H = elevation

P = pressure

V = velocity

𝜌 = density (assuming that it is incompressible)

g = gravitation constant

Fig. Sprue design

For two different elevations

𝑝1 𝑣12 𝑝2 𝑣22
ℎ1 + + = ℎ2 + + + 𝑓………………….…….10.3
𝜌𝑔 2𝑔 𝜌𝑔 2𝑔

f = represents the friction loss in the liquid

Continuity

Rate of flow is constant thus

𝑄 = 𝐴1𝑉1 = 𝐴2𝑉2…………………………………10.4

Where

Q = rate of the flow (m3/s)

A= is the cross-section area of the liquid stream

V = is the average velocity of the liquid

𝐴1 ℎ2
=√ …………………………………………….10.5
𝐴2 ℎ1

Assumption:

When

P1 =P2 & no friction (f= zero)

The equation 10.5 can be use in sprue and other location in

mold.
An important consideration in fluid flow in gating system is the
turbulence, Reynolds number equation used in calculations.

Video Sand casting digital production