Chills

Metallic members inserted in the

moulding sand.
Increase the solidification rate.
Promote directional solidification of
the casting.
Prevent internal voids or porosity
inside castings.

Classification of Chills
External Chills.
Internal Chills.

External chills are placed in the mould

walls.
Internal chills are placed within the
mould cavity and forms the part of
casting.

Chaplets:
Metallic spacers used to support a
core.
Placed in the mould between the
mould face and the core.
Material should be the same or nearly
the same of that of the castings made.
Chaplets are surrounded by it and
ultimately fused into it.

Various types of chaplets

Gating System:
The term Gating is defined as one of
the channels leads to mould cavity.
Gating system involves the flow of
molten metal from the ladle to mould
cavity.

Functions:
Enough molten metal reach the cavity.
Fill the cavity in shortest possible time.
Provide continuous, uniform feed of
molten metal without any turbulence.
To prevent slag, dross and other
materials.
To prevent mould erosion.
To achieve proper directional
solidification.

Elements of a gating
system:

1. Pouring basin.
2. Sprue.
3. Sprue base well.
4. Runner.
5. Runner extension.
6. Ingate.
7. Riser

Pouring basin:

Sprue:

Sprue Base well:

Acts as reservoir for metal at the
bottom of the sprue.
It reduce the momentum of the molten
metal.
The molten metal gains velocity, some
of which is lost in the sprue base well
by which the mould erosion is
reduced.
This molten metal then changes
direction and flows into the runners in
a more uniform way.

Runner:
located in the horizontal plane (parting
plane),
It connects the sprue to its in gates.
The runners are normally made
trapezoidal in cross section.

5. Runner Extension:
The runner is extended a little further
after ingate.
Trap the slag in the molten metal.

Gates:
Gates are the openings through which
the molten metal enters the molten
cavity. Also called the ingates.
Depending on the application, various
types of gates are used in the casting
design. They are
1. Top gate.
2. Bottom gate.
3. Parting gate.
4. Step gate.

Riser:
It is the passage made in the cope to
permit the molten metal to rise above
the highest point in the casting after
the mould cavity is filled up.
Functions:
They compensate for solidification
shrinkage.
Serves as heat source, so that they
freeze last and promote directional
solidification.

The common types of risers are:

Top Risers.
Internal Risers.
Blind Risers.

Risering System:

Functions:
It should have sufficient volume, as it should be
the last part of the casting to freeze.
It should completely cover the sectional
thickness that requires feeding.
The fluidity of the molten metal must be
adequately maintained.
It is designed such that the temperature gradient
can be minimized within the casting.
The solidification time of metal in riser should be
greater than in mould cavity.
It should derive sufficient feeding pressure either
by atmospheric pressure or metallostatic
pressure.

Gating System Design

Pouring Time
Choke Area

Gating Ratios
Sprue Area : Runner Area : Ingate Area
Slag Trap Systems

Risering Design Caines

Method
Surface Area to Volume ratio.
Chvorinov Proposed
Solidification time is proportional to
square of ratio of volume to surface
area of the casting.

Freezing Ratio

Freezing ratio > unity

Based on Chvorinovs rule, Cane

proposed empherical relation for
freezing ratio.

Y = riser volume/casting volume.

a, b, c = constants