Gating System

• Turbulent flow is generated while pouring the

molten metal into the mold which causes the
following problems:
– absorption of gases,
– oxidation of the metal, and
– erosion of the mold.
• Therefore gating systems should be designed to
minimize turbulent flow.

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 Gating System
• Short sprues are desirable, since they minimize
the distance that the metal must fall when
entering the mold.
• Rectangular pouring cups prevent the formation
of a vortex or spiraling funnel, which tends to
suck gas and oxides into the sprue.
• Tapered sprues also pre-vent vortex formation.

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 Gating System
• A large sprue well can be used to dissipate the
kinetic energy of the falling stream and prevent
splashing and turbulence as the metal makes the
turn into the runner.

4
 Gating System
• The choke , or smallest cross-sectional area in
the gating system, serves to control the rate of
metal flow. If the choke is located:
– near the base of the sprue, flow through the
runners and gates is slowed and flow is rather
smooth.
– at the gates, the metal might enter the mold
cavity with a fountain effect, an extremely turbulent
mode of flow, but the small connecting area would
enable easier separation of the casting and gating
system. 5
 Gating System
• Gating systems can also be designed to trap
dross (slag) and sand particles and keep them
from entering the mold cavity.
• Screens or ceramic filters of various shapes,
sizes, and materials can also be inserted into the
gating system to trap foreign material.
• Wire mesh can often be used with the
nonferrous metals, but ceramic materials are
generally required for irons and steel.
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Sprue well Runner well

2
5
Sprue well Runner well

2
6
Sprue well Runner well

2
7
Sprue well Runner well

2
8
Sprue well Runner well

2
9
Sprue well Runner well

3
0
Sprue well Runner well

3
1
 Rise
Riser
r
• A riser is an additional void in the mold that
also fills with molten metal.
• Riser is a reservoir of additional molten
metal that can flow into the mold to
compensate for shrinkage of the part during
solidification .
• The riser must be designed to freeze after the
main casting in order to satisfy its function.

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Rise
Riser
r

15
 Rise
Riser
r
• Live risers (also known as hot risers) receive the last
hot metal that enters the mold and generally do so
at a time when the metal in the mold cavity has
already begun to cool and solidify.
• Thus, they can be smaller than dead (or cold) risers,
which fill with metal that has already flowed
through the mold cavity.
• As shown in Figure, top risers are almost always
dead risers.
• Risers that are part of the gating system generally
live risers.
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 Rise
Riser
Dead
r Dead

Live

17
 Rise
Riser
r
• Open risers have the danger of solidifying first,
therefore they must be sized properly (larger) for
proper function.
• An open riser helps exhaust gases from the mold
during pouring, and can thereby eliminate some
associated defects.
• A blind riser that is not open to the atmosphere
may cause pockets of air to be trapped, or
increased dissolution of air into the metal,
leading to defects in the cast part.
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 Problems with
Problems Too
with Large
Too Riser
Large Riser
• The material in the riser is eventually scrapped
and has to be recycled; the riser has to be cut off,
and a larger riser will cost more to machine.
• An excessively large riser slows solidification.
• The riser may interfere with solidification
elsewhere in the casting.
• The extra metal may cause buoyancy forces
sufficient to separate the mold halves, unless
they are properly weighted or clamped
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 Problems with
Problems Too
with Small
Too Riser
Small Riser
• The drawbacks to having too small riser are
mainly associated with defects in the casting,
either due to insufficient feeding of liquid to
compensate for solidification shrinkage.

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 Riser Location
• A riser should be located in such a way that
directional solidification is obtained.
• Since the heaviest section of the casting solidifies
last, the riser should be located to feed this
section.
• The heaviest section will now act as a riser for
other sections which are not so heavy or thick.
• For small castings, a single riser can feed the
entire casting, but more than one riser is
required for large castings.
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 Vent holes
• As the metal flows into the mould, the air that
previously occupied the cavity, as well as hot gases
formed by reactions of the molten metal, must be
evacuated so that the metal will completely fill the
empty space.
• In sand casting, for example, the natural porosity of
the sand mould permits the air and gases to escape
through the walls of the cavity.
• In permanent-metal mould, small vent holes are
drilled into the mould or machined into the parting
line to permit removal of air and gases.
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 Gating System Design
• A good gating design should ensure proper
distribution of molten metal
• without excessive temperature loss, turbulence,
gas entrapping and slags.
• Slow Pouring Time: Solidification Starts
• Faster Pouring Time: Erosion will takes place
• So gating design is important and it depends
on the metal and molten metal composition.
For example, aluminium can get oxidized easily.
 Elements of Gating Systems
The term gating system refers to all passageways through which molten metal
passes and enter into the mould cavity.

The Gating system is composed of:

• Pouring Basin
• Sprue
• Runner
• Gates
• Riser
 Types of Gating
System
Main types of gates are following:

1. Vertical Gating System

2. Bottom Gating System

3. Horizontal Gating System

 Functions of Gating
System
• Fill the cavity completely

• Minimize turbulence

• Avoid erosion

• Remove inclusions

• Regulate flow

• Consume least material and less scrap

• Trap containments

• Establish directional solidification

 Factor Affecting Gating System
To achieve sound casting and other objectives following factors should be
controlled properly:

• The size, type, and location of sprue and runner.

• The size, number & location of gates entering mold cavity.

• The rate of pouring.

• The position of the mold during casting.

• The temperature and fluidity of the metal.

 Objective of the Gating System
The four main points, which enables a proper gating system, are:

• Clean molten metal: The mold cavity must be filled with a clean metal so
that it prevents the entry of slag and inclusions into the mold cavity, which
in turn minimizes the surface instability.

• Smooth filling of the casting cavity: If the mold has smooth filling then it
helps to reduce the bulk turbulence.

• Uniform filling of the casting cavity: If it has a uniform filling it means that
the casting fill is in a controlled manner.

• Complete filling of the casting cavity: Complete filling of the cavity makes
the metal thin with minimum resistance at the end sections.
 Elements of Gating System
1. Pouring basin : This is otherwise called as bush or cup. It is circular or
rectangular in shape. It collects the molten metal, which is poured, from the
ladle.
2. Sprue : It is circular in cross section. It leads the molten metal from the
pouring basin to the sprue well.
3. Sprue Well : It changes the direction of flow of the molten metal to right
angle and passes it to the runner.
4. Runner : The runner takes the molten metal from sprue to the casting.
Ingate: This is the final stage where the molten metal moves from the runner
to the mold cavity.
5. Slag trap : It filters the slag when the molten metal moves from the runner
and ingate. It is also placed in the runner
 Pouring basin
• A reservoir for the molten metal poured from the ladle.
• This is otherwise called as bush or cup.
• It is circular or rectangular in shape.
• It collects the molten metal, which is poured, from ladle.
• It prevent the mould erosion.
• Prevent slag and other impurities from entering the mould cavity.
Pouring Basin Proportions
 Design of Pouring Cup
This is a convention - in most of the cases pouring cup is cut manually in a
conical way, but there are some limitations of this pouring cup, which is cut
manually.
• One is the surface of this conical cup is rough and there will be sand
particles. When we pour the molten metal on this cup, small particles of
the sand they are eroded and they go inside the cavity.

• And another drawback is the molten metal swirls, it rotates, and finally, it
will create turbulence inside the cavity. So, these are the drawbacks of the
manually cut pouring cup.

Remedy: Ceramic Cups

 Pouring Cup
Dimensions
RoundOutlet
Inlet Diameter (inches) InletDiameter
and Round
(inches)Outlet Height (inches)
2 1 1.5
5 2.5 5.25
8 3 5.5
10 4 8

Rectangular Inlet and Round Outlet

Inlet Cross Section (inches) Outlet Diameter (inches) Height (inches)

3.06 x 3.56 1.28 4.59
4.13 x 5.25 1.50 5
5.50 x 6.25 2 6
 Sprue and Sprue Well
• Sprue : It is circular in cross section. It leads the molten metal from
the pouring basin to the sprue well.
• Sprue Well : It changes the direction of flow of the molten metal to right
angle and passes it to the runner.
 Runner

• The runner takes the molten metal from sprue to the Ingates of casting.
 Types of Runners
• Straight runner

• Tapered runner

• Step gate (may also act as feeder)

• Uniform size runner( may cause uneven distribution)

• Runner for even distribution of metal (reduction in size of runner after

each gate)
 Design of Ingates
• Multiple ingates systems are often employed

• A fillet should be used where an ingate meets the casting for

less turbulence

• Ingate length = 3 to 5 times of its width

• No curved ingates should be present in the casting

 Gating
Ratios
Gating ratio: sprue area : runner area : gate area

• Non-pressurized: has choke at the bottom of the sprue base, has total
runner area and gate areas higher than the sprue area. No pressure is
present in the system and hence no turbulence. But chances of air
aspiration is possible. Suitable for Al and Mg alloys.
In this, Gating ratio = 1 : 4 : 4

• Pressurized: gate area is smallest, thus maintaining the

Here
pressure throughoutback
the gating system. This backpressure generates
turbulence and thereby minimizes the air aspiration even when straight
sprue is used. Not good for light alloys, but good for ferrous castings.
In this, Gating ratio = 1 : 2 : 1
 Fluidity
• Fludity of metal is determined generally by sprial mold test.

• The fluidity index is the lengthof the solidified metal in the sprial Passage.

• Greater the length of the solidified metal, greater is its fludity.

 Fluidity of Molten
Metal
• Fluidity: The capability of a molten metal to fill mold cavities

• Viscosity: Higher viscosity decreases fluidity

• Surface tension: Decreases fluidity; often caused by oxide Film

• Inclusions: Insoluble particles can increase viscosity and decrease fluidity

• Solidification pattern: Fluidity is inversely proportional to the

freezing temperature range
 Factor Affecting Fluidity of Molten Metal

1. Mold design: The design and size of the sprue, runners, and risers affect
fluidity

2. Mold material and surface: Thermal conductivity and

roughness decrease fluidity

3. Superheating: The temperature increment above the melting point

increases fluidity

4. Pouring: Lower pouring rates decrease fluidity because of faster

cooling

5. Heat transfer: Affects the viscosity of the metal

Functions:
• Reservoir of molten metal
Riser
• Compensate during shrinkage for solidification

Location:
• The riser must not solidify before the casting.

• The volume of the riser or risers must be large enough to feed the entire
shrinkage of the casting.

• The pressure head from the riser should enable complete cavity filling.

• Risers must be placed, so that the liquid metal can be

delivered to locations where it is most needed.