Shrinkage cavity reduction in gravity casting process

Abstract

Casting defects is a prevalent issue in metal casting manufacturing industry. The presence of casting defects would adversely affect quality of cast and performance of casted components. In conjunction with Singapore Technologies Engineering (Land Systems) [STELS], this study focuses on minimizing shrinkage cavity defects in magnesium alloy billet produced via permanent mold gravity casting. This investigation aims to explore and apply the method of directional solidification in the minimization of shrinkage cavities through the use of numerical simulation and experimental results. Shrinkage cavities can render casted components unusable or cause large amounts of material wastage. Thus, minimizing this defect would result in minimization of waste. The experimental data from this study showed positive results in reducing the shrinkage cavity defects after improving the experimental set-up from the initial methods and practices in the company. The implementation of the new casting set-up has indeed benefitted the company in increasing casting yield of magnesium alloy billets.