Numerical Simulation and Experimental Validation of Melt Flow in the Naturally Pressurized Gating System

The main problem during the production of castings from aluminium alloys is presence reoxidation, which negatively affects final casting quality. Liquid metal surface reacts with surrounding atmosphere and oxide layer Al2O3 formed on its surface. occurs when entrained to internal volume melt by turbulence double layers are formed, also known as “bifilms”. Its formation related velocity gating system design. In paper, naturally pressurized was calculated designed. Effect filter media vortex element velocity, amount oxides, mechanical properties, porosity were observed. Designs 10 ppi 20 foam filters compared design without prove positive (or negative) effect thus oxides observed aid simulation software. Mechanical quantity pores, bifilm index EDX analysis evaluated after experimental casts. It proven that using in combination element, best results achieved.