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<p>The effect of gating system design on the inclusion population and size distribution in an aluminum-killed low-alloy advanced high strength steel casting was studied. A mold with four different gating systems: pressurized and non-pressurized with side risers, naturally pressurized with a side riser, and naturally pressurized with a top riser, was designed using computational fluid dynamics and solidification software. The design allowed inclusion populations in castings produced with each gating system to be compared during the same pouring event. Samples taken from different positions just below the top surface of each casting were analyzed using an SEM/EDS system with automated feature analysis capability to study the quantity, size, morphology, composition, and size distributions of the inclusions in each casting, as well as the porosity levels in the castings. The naturally pressurized gating systems produced the cleanest steel, having the lowest gate velocity and hence, lower area fraction of alumina inclusions, with an average of 91&#xa0;ppm and 81&#xa0;ppm alumina inclusions for the naturally pressurized with a side riser, and naturally pressurized with a top riser, respectively. The pressurized gating system produced the dirtiest casting with an average area fraction of 181&#xa0;ppm alumina inclusions. The average breaking energy of the castings at − 40&#xa0;°C showed little variation, ranging from 21 to 23 Joules.</p>

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Effect of Gating Design on Filling and Inclusion Control in an Al-killed Cr-Mo-Ni Steel

  • 期刊论文

  • 发表日期：

    2025年9月13日

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  • Kingsley T. Amatanweze,
  • Koushik Balasubramanian,
  • Soumava Chakraborty,
  • Viraj A. Athavale,
  • Mario F. Buchely,
  • Laura N. Bartlett,
  • Ronald J. O’Malley,
  • Daniel M. Field,
  • Krista R. Limmer,
  • Katherine M. Sebeck

摘要

The effect of gating system design on the inclusion population and size distribution in an aluminum-killed low-alloy advanced high strength steel casting was studied. A mold with four different gating systems: pressurized and non-pressurized with side risers, naturally pressurized with a side riser, and naturally pressurized with a top riser, was designed using computational fluid dynamics and solidification software. The design allowed inclusion populations in castings produced with each gating system to be compared during the same pouring event. Samples taken from different positions just below the top surface of each casting were analyzed using an SEM/EDS system with automated feature analysis capability to study the quantity, size, morphology, composition, and size distributions of the inclusions in each casting, as well as the porosity levels in the castings. The naturally pressurized gating systems produced the cleanest steel, having the lowest gate velocity and hence, lower area fraction of alumina inclusions, with an average of 91 ppm and 81 ppm alumina inclusions for the naturally pressurized with a side riser, and naturally pressurized with a top riser, respectively. The pressurized gating system produced the dirtiest casting with an average area fraction of 181 ppm alumina inclusions. The average breaking energy of the castings at − 40 °C showed little variation, ranging from 21 to 23 Joules.