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. 2022 Jun 30;15(13):4620.
doi: 10.3390/ma15134620.

Gating System Optimization for EV31A Magnesium Alloy Engine Body Sand Casting

Andrzej Kiełbus  1 , Robert Jarosz  2
Affiliations

Gating System Optimization for EV31A Magnesium Alloy Engine Body Sand Casting

Andrzej Kiełbus et al. Materials (Basel). .

Abstract

The research presented in this paper aimed to change the existing gating system that would enable the engine body casting, from a new EV31A magnesium alloy, of the required quality. For this reason, the casting process simulations used the MAGMASoft software, followed by the experimental validation of the achieved results. The results achieved in the first stage of the cast computer simulation enabled the identification of potential problems and factors that reduce the casting quality. However, the proposed design modifications eliminated the inadequate delivery of liquid metal to the casting's critical areas by adequately controlling the mold cavity filling and solidification process. The experiment validated the simulations of the computer casting defects at the various stages. The results enabled the new EV31A magnesium alloy to be implemented in industrial production.

Keywords: EV31A; MAGMASoft; foundry; gating system; magnesium alloy; sand casting; simulation.

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Conflict of interest statement

The authors declare no conflict of interest.

Figures

Figure 1
Figure 1
(a) 3D casting model with gating system; (b) 3D chromium-nickel tube collector model.
Figure 2
Figure 2
(a) Casting mold during assembly; (b) engine body sand casting with the gating system.
Figure 3
Figure 3
Porosity evaluation procedure: (a) gray input image; (b) detection, image for measurement.
Figure 4
Figure 4
Stage 1 Liquid metal-air entrapment: (a) 20% of mold filling; (b) 35% of mold filling.
Figure 5
Figure 5
Stage 1 Liquid metal-air entrapment-100% of mold filling: (a) whole casting; (b) area A; (c) area B.
Figure 6
Figure 6
Stage 1 (a) Porosity in feeding gates areas; (b) Corresponding X-ray image.
Figure 7
Figure 7
Stage 1 (a) Oxide impurities; (b) porosity in the areas marked in Figure 5a (LM).
Figure 8
Figure 8
Stage 2 (a) Gating system with changed feeding gates and risers; (b) changed riser WD2; (c) changed riser WD4.
Figure 9
Figure 9
Stage 2 Liquid metal-air entrapment: (a) 20% of mold filling; (b) 35% of mold filling.
Figure 10
Figure 10
Stage 2 Porosity in the feeding gate areas.
Figure 11
Figure 11
Stage 3 Changed filter system with ceramic filters.
Figure 12
Figure 12
Stage 3 (a) Filter system without ceramic filters; (b) Filter system with ceramic filters.
Figure 13
Figure 13
Stage 4 Feeding system through the gravity top risers.
Figure 14
Figure 14
Stage 4 Total Porosity criterion: (a) the system without feeding elements; (b) the system with top feeding risers.
Figure 15
Figure 15
Stage 4 Microporosity criterion: (a) the system without feeding elements; (b) the system with top feeding risers.
Figure 16
Figure 16
Stage 4 Porosity: (a) lower casting part; (b) top casting part.
Figure 17
Figure 17
Stage 4 Casting-collector area: (a) porosity; (b) leakage (SEM).
Figure 18
Figure 18
Stage 5 Cast iron chillers with increased thickness.
Figure 19
Figure 19
Stage 5 Total Porosity criterion: (a) 10 mm chiller thickness; (b) 15 mm chiller thickness.
Figure 20
Figure 20
Stage 5 Microporosity criterion: (a) 10 mm chiller thickness; (b) 15 mm chiller thickness.
Figure 21
Figure 21
Stage 5 Soundness criterion: (a) 10 mm chiller thickness; (b) 15 mm chiller thickness.
Figure 22
Figure 22
Stage 5 Casting critical areas: (a) XRD results; (b) low porosity (LM).
See this image and copyright information in PMC

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