SIMULATION, SAND CASTING AND NON – DESTRUCTIVE TESTING OF ALUMINIUM ALLOY

Abstract

Sand casting is one of the oldest manufacturing processes in metallurgy which usually results in porosity, shrinkage and cold shut defects due to disturbance in melt flow .To make this process rejection free and efficient, gating and riser system play very important role. In this work, multiple gating and riser systems were designed for Aluminum alloy (LM13) considering foundry man’s experience, literature based calculation methodology and solid cast’s wizard. Then by using solidcast, simulation was run and results were generated. On the basis of the results, some of the designs were selected and then castings were produced and compared using non - destructive testing (visual, DPT, ultrasonic and dimensional). From this experimentation it was concluded that simulation reduces effort, time, cost and increases the efficiency & yield of the process.