Casting Slides 131-208 (End)

Types of gating system, and mold
filling time
ME30605-Casting, forming and welding

Gating system
The elements of the basic common gating system are the pouring basin,
down sprue, sprue well, the runner, and ingates.
Objective of the Gating System :
 Clean molten metal  prevents the entry of slag and inclusions into the
mold cavity
 Smooth filling of the cavity  to reduce the bulk turbulence
 Uniform filling of the cavity  casting
fill is in a controlled manner
 Complete filling of the cavity  makes
the metal thin with minimum resistance
at the end sections.

Gating system
Elements of gating system to prevent impurities
• Pouring cup (basin) and Dam
• Strainer
• Splash core and Skim core
• Relief sprue
• Skim bob
• Runner extension, etc.

Gating system: Types
Depending on the orientation and position,
Top gating system
Bottom gating system
Vertical gating system
Horizontal gating system
• Molten metal from pouring basin • The molten metal enters from bottom to
is fed directly into the mould the mould cavity
cavity. • Minimizes turbulence and erosion in the
• The hottest metal remains at the mould cavity
top of casting  promotes • Provides unfavorable temperature
directional solidification from the gradients that do not promote directional
casting towards the gate solidification
Middle gating system
Parting line gating system

Gating system: parting gates

Gating system: Aspiration effect
If the pressure in the liquid metal stream falls below atm. pressure  gases
from the mould will enter in the molten metal stress  produce porous
casting  Aspiration effect.
To avoid –ve pressure at point 2, the sprue Avoid the entrainment of
should be taper. air or gases in the metal
stream
A3 hc
R 
A2 ht
Air aspiration induced by liquid flow in the straight
sided sprue
Natural flow
of free Liquid flow in
ME30605-Casting,
the tapered forming and welding
falling liquid
sprue
Gating system: Mold filling time
The gating system should be designed such that it may be necessary to fill
the mold before the freezing of the thinnest section.
Mold filling time tf = Vol. of casting / Vi Ai
Top gating: Gating ratio
V W
tf  
Ai 2 ght  . Ai . 2 ght
Vi  2 ght
Ai = 0.5 in2

Gating system: Mold filling time
Bottom gating:
• Applying Bernoulli’s equation at 1 and 3
• At 3 and 4 (v4 is very small and all K.E is lost at 3)
Vg  V3  2.g .(ht  h)
• Metal level moves up (dh) in time dt Am .dh  A g .Vg .dt
1 dh Ag
.  .dt
2 g ht  h Am

At t=0, h=0 and t=tf, h=hm
1 dh A
.  g .dt
hm tf 2 g ht  h Am
1 dh Ag
2g 
0

ht  h Am 
0
dt
Am 1
tf  . .2( h t  ht  hm )
Ag 2 g
Empirical relation (pouring time)

 T 
t  K  0.95  . W Gray cast iron<1000 lb K is fluidity factor
 0 . 853 
T is average thickness (in)
 T 3
t  K  0.95  . W Gray cast iron>1000 lb W is weight (lb)
 0.853 
t  k. W Steel casting k = 1.2 for 100 lb casting to

0.4 for 100000 lb casting

Example: Mold filling time
Two gating designs for a mold of 50 cm x 25 cm x 15 cm are
shown in figure. The cross sectional area of the gate is 5 cm2.
Determine the filling time for both the designs.
Top gating: Bottom gating:
Vol. Am 1
tf  tf  . .2( h t  ht  hm )
AgV3 Ag 2 g
V3  2 gh ht = 15 cm hm = 15 cm
h = 15 cm
Top gating

Bottom gating
Steps for gating design:
Higher limit of filling time (slowest filling) is decided by the need to avoid
premature freezing in thin sections before complete filling.
Lower limit of filling time (fastest filling) is decided by the onset of surface
turbulence.
1. To limit the velocity of melt at the ingate within a critical limit (1.0
m/sec for ferrous metal and 0.5 m/sec for aluminum alloy) to achieve
smooth flow in the mold. (i.e. 50-mm fall for ferrous and 13-mm fall
for aluminum alloy)
2. Slow rising speed in bottom gate filling against the melt head in the mold
and hence reduce erosion and splash.

3. Ingate should never be placed directly opposite to core (avoid core
erosion)
Fast stream striking in a direction perpendicular to the face of
impingement should be avoided.
Vimp-limit – limiting value of impingement velocity for the onset of the mould
erosion, Vimp – velocity of impingement, nimp – unit vectors along the direction of
impingement and nf – unit vectors normal to the casting face of impingement.
4. Multiple ingates (with reduced diameter of the ingate) to distribute melt

so that the distance of flow from any ingate to the farthest point filled by
that ingate is less than fluidity distance.

5. Introduce molten metal into the mold cavity at
locations such that directional solidification
promoted.
• The best position is thick section which
allow molten metal to flow to other sections
with minimal cooling.
6. Ingate must be easy to fettle.
• Size of the ingate must be small compared to the connected portion of
the casting to avoid casting breakage or cracks during fettling.
• Preferably the ingate junction should a flat surface with a thick
section of the casting.
• When several ingates are present, one that is most likely to cause
damage determines the criteria assessment value defined as,
tgi – thickness of the ingate i
tci – thickness of the connected portion of the casting

7. It should be commercially practicable with maximum casting yield.
• Volume of the gating system must be minimized.
Nc – No. casting cavities per mould
vc – Volume of each cavity
vg – Volume of the common gating system for all the
cavities in the mould.

Issue with multiple ingate system (parallel finger ingates)

Uniform flow with multiple ingate system
Pool in system
Backswept runner
Central sprue
System using
parallel runner
with angled
ingates
Tapered runner ME30605-Casting, forming and welding
Fluidity

Fluidity
Fluidity is the ability of liquid metal to flow and fill the mold. (runability)
The distance to which a metal, when

cast at a given temperature, will flow
in a given test mould before it is
stopped by solidification.
Flowability limited by heat transfer.

Fillability limited by surface tension

Factors influencing fluidity
Characteristics of alloy solidification
Viscosity of liquid metal
Heat content of metal
Mold properties and pouring condition

Pure metals have a sharply defined freezing point and transform from
liquid to solid in a single step.
The best fluidity is observed at pure components and eutectics.
The poorest fluidity is observed when the solidification range is high.
Long solidification
range  metal is in a
mushy state consisting
of dendrites surrounded
by liquid  low
fluidity.

Relationship between
composition and fluidity
of lead-tin alloys
Fluidity vs. Carbon

content at eutectic
composition

Solidification modes
Pure metals and eutectic alloys  Solidification occurs by planar
growth from the walls toward the centerline, and flow stops when growth
causes the planar fronts to meet.

Small quantity of alloying elements cause breakdown of the smooth front
between solid and liquid pure metals  cause nonplanar growth.
Columnar dendrites (with a mushy zone) grow from the edges towards
the centerline and the columnar dendrites pinch off at a lower solid
fraction than in pure metals.

When the alloy content is sufficiently great and the freezing range is widest
 they generally solidify as equiaxed dendrites.
Equiaxed crystals can be carried in suspension.
Flow stoppage occurs when the equiaxed grains at the flow tip form a solid
network that can resist flow (typically occurs at 20–50% solid).

Between the extremes in Fig. d and e, solidification occurs by mixed-mode
mechanisms such as the columnar-equiaxed mode.
It has an Lf between that of the fully columnar and equiaxed modes.


Constitutional under cooling
As the thermal gradient during solidification of the alloy decreases 
constitutional undercooling increases  more instability at the solid-liquid
interface  high probability of formation of an equiaxed dendritic
microstructure.
Actual melt
temperature
attains
equilibrium
temperature only
at the interface
Actual melt
temperature is
lower than the
equilibrium
temperature 
difference is
ConstitutionalME30605-Casting, forming and welding
under cooling
Viscosity
Viscosity depends on metal types, composition, and the instantaneous
temperature.
High viscosity reduces fluidity.

Heat content
The most dominant factor is the first temperature of the molten metal.
Fluidity of alloys related with superheat (heating above liquid temperature
but still in the liquid phase)  Superheat determines the quantity of heat to
be absorbed before freezing.
Latent heat (L) Super heat
Effect of superheat on
Heat content   mV L  Cm(Tp  Tm) fluidity in pure metal
Al  257.5 cal / dm3

Mg  166 cal / dm3
Fluidity of magnesium is
2 times lower than that of
ME30605-Casting,
aluminum forming and welding
Mold properties and pouring condition
Thermo physical property i.e. conductivity of the mould and temperature of
the mould
Mould with high heat diffusivity transfers heat faster from the molten metal
 early freezing  low fluidity.
Gas permeability of the mould and state of the mould surface
Rough surface of the mould hinders metal flow.
Height of sprue  higher metallostatic pressure  higher velocity of
molten metal  higher fluidity.
Back pressure reduces metallostatic pressure due to compression of air and
gases generated.

Different casting defects

Casting defects
• Gas Porosity: Blowholes, open holes, pinholes

• Shrinkage defects: shrinkage cavity
• Mold material defects: Cut and washes, swell, drops, metal
penetration, rat tail
• Pouring metal defects: Cold shut, misrun, slag inclusion
• Metallurgical defects: Hot tears, hot spot.

Casting defects: Inclusions
• Sand, slag, dross, oxides or other materials embedded in casting
• Solutions:
• Quality control during melting by degassing, design of gating system
to minimize turbulence, erosion of mold wall and aspiration, and
adoption of filtration technique.

Casting defects: Hot tears / cracks
• Appears during casting of long freezing range alloys.
• Results due to liquid films (tearing) at the grain boundary in the later part
of solidification and strain at this stage.
• If the solidifying metal does not have sufficient strength to resist tensile
forces during solidification, hot tears will appear.
• It looks like cracks and called as hot tears or hot cracking.
• Affecting parameters  Geometry and size of casting, mold material,
alloy composition, grain size, pouring and mold temperature, gas content,
etc.

Laboratory experiment

Casting defects: Blow holes and pin holes (gas porosity)
• Usually caused by entrapped gases (CO, H, N or steam)
• Voids caused by entrapped gas that was dissolved in the molten metal or
air and moisture in the mold itself.
• Air / gas can be trapped in: Shot sleeve, Gating system, Die cavity
• Pinhole is very tiny hole, some could be seen on the surface.
• Subsurface blowhole can be only seen after machining or grinding.
• Solutions:
• Proper melting with degassing, high permeable mold and core,
• No slag entrapment, reducing moisture content in the mold, avoid
aspiration,

Casting defects: Macro and micro porosity due to shrinkage
• Most metals and alloys contract during solidification.
• If liquid and solidification shrinkage is not compensated by riser
• Due to metal freezing and blocking the flow of metal to the last sections
of the casting before solidification.
• Usually appear at the top of hot spots, or isolated pools of hot liquid.
• Solutions:
• Proper riser design and placement for directional solidification.
• Chemistry of the liquid metal.
• Use of chill mold.

Casting defects: Cold shut
• This occurs when metal coming from different directions in the mold do
not fuse properly.
• It typically looks like a crack in the casting.
• Cold metal results in a lack of fluidity.
• Solution:
• Proper chemistry of the metal with superheat.
• Design of gating system. Good permeability of mold.

Casting defects: Misrun
• The misrun is the unfilled portion or space in the mold.
• Misruns occur when the liquid metal is too cold to flow to the extremities
of the mold cavity before freezing and solidifying.
• The reasons for premature solidification are similar to those for cold shut.
• If you have a misrun, check:
• Mold design
• Gating system design and
• Molten metal fluidity
• Solution:
• Proper chemistry of the metal with superheat.
• Design of gating system.
• Good permeability of mold.

Casting defects: Rat tail
• It is a mold expansion defect.
• It is a milder form of expansion failure of the mold surface during rapid
heating.
• Rat tails, or veins, appear as an irregular line or crack on the casting.
• Rat tails usually occur on the surface of the mold bottom.
• Reason:
• High clay content having deformation capacity
at high temperature.
• Solutions:
• Additives to counter expansion include
wood flour, coal dust and cereal binders

Casting defects: Scab
• Scabs are rough, irregular projections on surface of castings containing
embedded sand.
• Scabs occur when a portion on the face of mold or core lifts and metal
flows underneath in a thin layer.
• Reasons  Using too fine sand, low permeability or moisture content,
uneven mold ramming or by intense local overheating.
• Solutions  reduced by mixing additives (sea
coal, wood flour or dextrin) in the sand,
providing uniform ramming and pouring with
correct velocity.

Casting defects: Metal penetration and sand burn
• Metal penetration occurs when liquid metal penetrates gaps in the
molding sand.
• Sand burn is due to mold-metal reaction which chemically bonds sand to
the casting surface.
• Solutions: Fine grain size, sufficient sand strength to withstand
metalostatic pressure, high refractoriness of sand, mold coating, etc.

Casting defects: Mismatch
• Misalignment of pattern and improper handling of mold.
• Reasons:
• Improper closing of the mold
• Improper core prints
• Incorrect chaplet size and core setting
• Pattern non-alignment in the cope and drag
• Loose work dowel pin in the loose pattern, etc.

Casting processes

Die casting
High pressure hot chamber die casting (up to 20MPa)
Applicable for zinc and other low melting point alloys that does not affect
and erode metal pots cylinders and plungers.
Process sequence:
Mold close  Clamping  Idle-1  Slow shot  Quick shot  Hold  Mold
open  Idle-2
Components:
• Casting mold or die with core, Clamping unit, Injection unit, Hydraulic system

Die casting
High pressure hot chamber die casting (up to 20MPa)
Process parameters:
• Plunger pressure
• Plunger velocity
• Clamping force
• Die lubrication
• Molten metal temperature and
• Solidification time

Die casting
High pressure cold chamber die casting (upto 200 MPa)
• Injection system is not submerged in molten metal.
• A charge of metal sufficient for a single casting is poured in to the sleeve 
Plunger forces the charge through the runner channels.
• Minimizes the contact time between the injector components and the molten
metal  Extends the life of the components.
• Iron contaminant is much lower.
• However the entrainment of air into the metal generally associated with high-
speed injection can cause gas porosity in the castings.
• Applications: steel castings along with aluminum and copper based alloys are
produced by this method.

Die casting
Low pressure die casting (upto 130 kPa)
• Die is positioned above a sealed furnace containing molten metal.
• A refractory-lined riser extends from the bottom of the die into the molten metal.
• Supply of low pressure air makes the molten metal rise up the tube and enter the
die cavity with low turbulence.
• Metal solidified  Air pressure released  Metal still in the molten state in the
riser tube to fall back into the furnace.
• Applications:
• High quality castings, of
aluminum alloys, along with
magnesium and other low melting
point alloys are usually produced.

Die casting
• Alloy steels (die steel having 425-460 HB) are used for dies and cores having high
temperature strength and wear resistance.
• Die material properties  low thermal expansion, higher Young’s modulus and
fatigue strength to increase the die life.
• To prevent soldering, better surface finish and facilitate casting release  die and
core face is lubricated by graphite, boron nitride, water based silicates etc.
• Die is also water circulated through channels to reduce the die temperature.
• Metallic movable cores with the dies can used for simple cylindrical cavities, and
the complicated cavities can be created by using salt core. Use of sand cores are
avoided due to high pressure.
• Tapering of 0.2% to 2% are recommended for die outer surface and the core for
easy withdrawal of the casting component minimizing the damage to the die.
• The air inside the die is vented through the mould joint and core-die joints by the
slow shot of the plunger.
• To minimize the gas porosity, oxygen is introduced to swept air from the die cavity
before injection.
Die casting: Advantages
• Thin walled complex casting of light metals e.g. Al, Mg and Zn (low meting
temp alloy). e.g. cases of cell phone and laptop, small automotive parts like
steering wheel, airbag housing and oil pan.
• Less porosity compared to green sand mould casting due to absence of
moisture.
• Produces fine grain micro-structure superior to sand casting due to very
rapid solidification rate (100-500 °C).
• Very good surface finish due to fine polished surface of the metal dies and
cores).
• Mechanized and hence production rate is higher.

Die casting: Disadvantages
• Very high initial cost of the machine, control system and die material
compared to tools used in sand casting
• Complicated internal cavities are normally impossible to cast.
• Only metals with low melting point can be cast.

Squeeze casting
Squeeze casting is a net shape fabrication technique under high pressure
(50-150 MPa). Also known as liquid forging or liquid stamping.
Process sequence:
1. A pre-specified amount of molten metal is poured into a preheated die
cavity, located on the bed of a hydraulic press.
2. The press is activated to close the die cavity and to pressurize the liquid
metal until complete solidification
3. The upper mould/punch is withdrawn and the casting is ejected

Squeeze casting: Classification, Applications and Parameters
Two basic forms of the process depending on whether
• The pressure is applied directly on to the solidifying cast product via an
upper or male die (punch) or
• The applied pressure is exerted through an intermediate feeding system
• Applications: Automotive industry in producing aluminum front steering
knuckles, chassis frames, brackets or nodes. High capacity propellers for
boat-engine.
Parameters:
• Type of casting equipment Direct squeeze Indirect squeeze
casting mode casting mode
Melt volume
• Pressure level
• Timing of pressure
application
• Pouring temperature ME30605-Casting, forming and welding
• Die temperature
Squeeze casting: Classification
1. Direct squeeze casting mode
Without metal movement:
• Suitable for ingot type components where there is no metal movement
With metal movement:

• Involves metal movement, also known as the backward process
• More versatile and can be used to cast a wide range of shaped
components.

Squeeze casting: Classification
2. Indirect squeeze casting mode
Further classified depending upon the clamping and injection direction
• Horizontal die closing and vertical injection
• Vertical die closing and horizontal injection
Horizontal die closing and vertical injection

a. Prevent inclusion of air: venting of air during complete upward hill
filling technique
b. Enable pouring and clamping at same time to minimize cycle time

Squeeze casting: Advantages and issues
• The hydraulic press load are much lower than required for conventional forging
or stamping.
• Squeeze cast shows isotropic material properties compared to conventional
forged or stamped products.
• The products are free from internal shrinkage and gas porosity, resulting from the
influence of plastic deformation under pressure during solidification.
• High cooling rate due to close contact between metal and die under pressure 
Fine grained micro-structure with better surface finish  higher strength to
weight ratio with improved fatigue properties.
• Near net shape manufacturing with higher casting yield.
• Process is limited to low melting point metal like aluminum, its metal matrix
composites and bimetals.
• The narrowest walls are limited to 4 mm thickness and the machines are slower
than conventional high pressure die casting.
Thixomoulding
• The process is analogous to plastic injection molding.
• Magnesium chips are fed through a feed screw under Ar gas 
progressively heated in the screw  inject in to the die once the material
reached the desired consistency at the front of the screw (typically only
5–10% solid fraction)
• It does not require melting facilities as the material is processed from the
solid.
• Product with high mechanical properties or complex shape.
• Applications: for making super-thin enclosures for laptops and other
small electronic devices. Competitor to injection molding and die-casting
in a wide variety of applications.

Thixomoulding: Grain structure
• With continuing shear and time during solidification, dendritic
morphology becomes rosette due to ripening and abrasion with other
grains.
• Ripening proceeds during further cooling.
• With sufficient slow cooling and high shear  particles become
spheroidal
• Spheroidal microstructure can be achieved by controlling
• Temperature of the melt,
• cooling rate,
• stirring (time, type, speed), etc.
Initial
dendritic dendritic Ripened
growth Rosette Spheroidal
fragment rosette

Centrifugal casting - horizontal
• In centrifugal casting, molten metal is introduced into the mould which is rotated
during solidification of the casting.
Fc r 2 2
r    2 0.011rN 2
G factor      N  r in m and N in rpm
Fg g g  30  g
• For a particular diameter of casting the rpm should be chosen such that the G
factor should be sufficient
 to prevent raining as the metal passes over the upper half of the mould,
 to spread the liquid metal through out the length by compression of liquid
against the mould wall without slip and True centrifugal casting (horizontal)
 to prevent instability without
tearing the shell due to higher stress
Fc

Centrifugal casting - horizontal
• In most practice, 20-100G
are commonly quoted for
true centrifugal casting.
• The high centrifugal force
keep the outer surface in
touch with the metallic mold
 increases the heat transfer
rate.
• The wall thickness can be
controlled simply by
controlling the volume of the
liquid metals during pouring.
• Applications:
• Rollers, rings, hollow
cylinders, pipes and tubes
are manufactured by this
technique without the use ME30605-Casting, forming and welding
of cores.
Centrifugal casting – vertical
• In vertical casting method, the spinning die spins about a vertical axis.
• Vertical castings may achieve O.D. shaping by inserting graphite, sand, or
ceramic molds into the die  significantly reduced post-processing, like
machining or fabrication.

Centrifugal casting – vertical
• Vertical axis true centrifugal casting has a tendency to form
a parabolic bore due to the gravitational component of the
force acting on the metal.
• The effect is defined in the expression by Donoho
2 2
ht  hb  H  2 N 2 (r t rb )
• Machining allowance is needed to produce the parallel
bore and can be expressed as

b  rt  rb  1
2N2 H 
D
where, D   rt  r b 
• For regime below 10 mm line, the extra
machining become so severe.
• Other routes such as horizontal spinning or
conventional static casting using internal
core have to be considered.

Semi-centrifugal casting
• Axisymmetric components of varying internal diameter or irregular wall
thickness are fabricated by using central core in a rotated mould.
• The centrifugal force helps in feeding the liquid metal to capture the
intricate shape of the mould.
• The centrifugal force acting on the casting metal eliminates the porosity
and shrinkage cavities.
• However, the G-factor is less than 15G to avoid the excessive flashing of
liquid metal at the parting surface.

Centrifuging casting
• In centrifuging casting process, multiple number of mold cavities are
placed at certain distance from the axis of rotation.
• The molten metal is poured from the center and is forced into the mold by
centrifugal force.
• The properties of the casting vary by distance from the axis of rotation.
• The various process variables influencing the casting quality in true
centrifugal, semi-centrifugal and centrifuging casting processes are:
• speed of rotation
• pouring temperature
• pouring speed
• mould temperate

Q. If G-factor of 120G is necessary to produce a hollow cylindrical
part in true centrifugal casting in a mould having inner diameter of
350 mm and length of 6 cm, what rotational speed is needed?
What will be the thickness of the hollow cylindrical casting if 9.4

kg of metal is poured in liquid state having density 2.3 gm/cm3, and
the total volumetric shrinkage is 0.05.

Investment casting (lost wax casting)
• Precision casting  very
good surface finish and
close dimensional
tolerance.
• The pattern in the
investment casting has the
dimensional allowance to
compensate its own
volumetric shrinkage as
well as solidification
shrinkage of the cast
metal.

Investment casting (lost wax casting)
• The application of investment casting is principally in the field of
relative small components. (most emphasis on intricate parts
weighing 1 gm - 0.5 kg)
• Thickness of 0.75 mm or even less can be achieved with complex
shape.
• Tolerance of around ± 0.15 mm with surface finish in the range of
0.8-3.2 μm can be commonly achieved
• All cast alloys can be fabricated
• Initial tool cost is very less, still not suitable for mass production.
• The preheat temperature has strong influence on casting
dimension.

Ingot casting
• The casting of ingots is a discontinuous process.
• The ingot molds are filled individually by top pouring (down-hill
teeming) or in batches by a central feeder through runners in the
base plate (up-hill teeming).
• Up-hill teeming: low rising speed of the steel in the mold reduces
cracks and surface defects when casting critical steel grades.

Advantages and disadvantages of uphill and downhill casting
Uphill casting with casting
Downhill casting
powder
- Additional consumption of cast - Surface defects
materials to central riser and - Poorer quality steel
runner. - Slower casting process
- Additional cost to make riser and - More wear and tear of the molds
runner + Cheaper casting
+ Better surface quality without
cracks
+ Several ingots can be cast at the
same time (batch production)
+ The problem with the centering
of the melt stream is eliminated.

Ingot casting: Classification
• The solidification of an ingot progresses from the bottom (cooled
by the base plate and the mold) to the top of the ingot.
• Ingots are mostly classified as killed, capped and rimmed ingot
• The ingot weights and sections are fixed by the capacity of the
primary rolling mill. The ingot size may vary from 4 to 30 t, or
even higher for forging.

• Killed steel is fully deoxidized prior to pouring into the mould.
Almost all steel grades containing >0.3% C are killed.
• Deoxidizers react with oxygen and form metallic oxides, which
float to the top of the molten bath to form a slag layer.

• In a rimmed steel, sufficient deoxidizing agents are added prior to
pouring to provide only minimal control over the gas level.
• Most steels containing between 0.06 and 0.15%C are rimmed
steels.
• The gases evolved form blowholes even in the bottom half of the
ingot.

• Capped steels are variants of rimmed steels.
• an outer surface relatively free of blowholes is produced, and
compositional segregation that occurs in the ingot centre is
reduced compared to a rimmed ingot.
• This process is particularly advantageous for steel with >0.15%
C.

Continuous casting
• The molten metal is poured directly into a casting machine to
produce billets, blooms or slabs.
• Continuous casting eliminates the need for primary and
intermediate rolling mills, soaking pits and the storage and use of
large numbers of ingot molds.
• Liquid steel flows out of the ladle (1) into the tundish (2), and
then into a water-cooled copper mold (3).
• Advantages:
• Yield improvement
• Energy conservation (direct
production of semi-finished
products)
• Savings in manpower

Continuous casting: Features
• Tundish to 1. Control the flow of melt into the chill mold
• 2. Help in positioning the melt flow to mold
• 3. Function as a slag separator
• Oscillating water-cooled copper mold:
• This mold is to form a solidified steel shell having sufficient
strength to prevent breakouts below;
• Mold oscillation creates a relative movement between strand
and mold, and prevents metal sticking to the mold surface.
• Stripping is facilitated by providing
an adequate lubricant (casting
powders or oil) at the steel meniscus.
• This lubricant is also essential to
maintain a high heat extraction and
prevent breakouts.
Continuous casting: Features
• Tapered mold walls to accommodate the strand shrinkage over
the mold length of 700 mm.
• On leaving the mold, the strand is cooled by water sprays and is
supported by rolls to prevent bulging until solidification is
complete
• Modern casters are curved type machines which are cheaper and
easier to accommodate in the plant than the original vertical
machines.
• The curved strand is straightened
by rollers after complete
solidification and cut to the
required length for further
processing in the rolling mills.


Casting Slides 131-208 (End)

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Casting Slides 131-208 (End)

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Types of gating system, and mold

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• At 3 and 4 (v4 is very small and all K.E is lost at 3)

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Empirical relation (pouring time)

t  k. W Steel casting k = 1.2 for 100 lb casting to

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4. Multiple ingates (with reduced diameter of the ingate) to distribute melt

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ME30605-Casting, forming and welding

ME30605-Casting, forming and welding

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The distance to which a metal, when

Flowability limited by heat transfer.

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Fluidity vs. Carbon

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Al  257.5 cal / dm3

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• Gas Porosity: Blowholes, open holes, pinholes

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With metal movement:

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Horizontal die closing and vertical injection

ME30605-Casting, forming and welding

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ME30605-Casting, forming and welding