Effect of Gating System Design on the Quality of Aluminum Alloy Castings

In this paper, a naturally pressurized gating system has been designed to reduce the turbulence of the melt during casting. The influence of gate dimensions, foam filters, a trident gate, and a vortex element were evaluated. Their effect on melt velocity, flow characteristics, number of oxides, casting properties, and mechanical properties were observed. ProCAST Simulation software v.2023 and a water flow test were also evaluated to assist in the experimental evaluation of the castings. Melts showed a relationship between melt velocity and porosity of castings. Quantitative evaluation of the surface porosity showed a trend of decreasing porosity with decreasing melt velocity. The greatest reduction in the melt velocity was achieved by a M4 design, which was associated with the highest reduction in the oxides. The pores analyzed proved the presence of oxide layers on their inner surface and a possible theory of pore formation when the initiator of porosity is entrained double oxide layers. The best metal yield was achieved with M1, but the difference between M2 and M4 was negligible (2–5% yield difference), so it can be stated that the beneficial effect of the M4 design in providing the best quality castings is not negated by the increase in metal yield.