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Steel casting pouring times

Steel gating part 1
The gating system is the part of the mould which allows quick and quiet mould filling
characteristics. The quickness will ensure that total mould filling is made before
problems with frictional loss and or metal fluidity occur which may result in short
pouring or feint runs. The quietness will ensure an absence of turbulence, which in
turn will minimise mould erosion, gas entrapment and potential chilling of the metal
during pouring and cold lapping.

A number of gating systems are available but it seems that some smaller jobbing steel
foundries still prefer to gate using experience as opposed to exercising some form of
standard policy and procedure. Part of this reluctance may be due to the time available
for a one off casting so it is the purpose of this module is to propose a method of
calculating pouring time and cross checking this with a recommended rate of rise in the
thinnest casting section.

Scholers empirical formula

Based on Sobolovs initial work Scholer
Ts = S * (VG) ^0.333 modified the work following a detailed table
of good casting results from Dubitsky.
Where
The result of this evolved a means of
Ts = preferred pouring time (sec). determining optimum pouring times within a
S = Coefficient foundry which would address all the non
V = Mean casting thickness (mm). tangible issues of charge materials - ladle
G = Weight to be poured (Kg). practice moulding material and casting
shape.
For casting size ranges, Barbence and Koutecky
reported suggested ranges for S based on repeated For best results it is
production of good castings over time. recommended that
actual pouring times are
For castings, 10 to 50 tonnes S = 1.8~2.8 recorded and listed
1 to 10 tonnes S = 1.2~2.0 against these
up to 1 tonne S = 0.9~1.5 influences.

Based in the results a

Based on normal pouring temperatures of over plus 50 standard deviation will
Deg above melting point Dubitsky introduced the result from records of
following influences for S good castings having no
gate affected defects.
Bottom gate Side gate Top gate
1.3 1.4 1.5~1.6
In addition to the optimum or desired pouring times the steel may have to travel through
varying section thickness. The degree of section change will then either add to or
reduce the velocity of the metal flow. If the section decreases then the velocity
increases and visa versa. Any increase in metal velocity (which is a measurement of
speed in cm/sec) may increase the risk of gas and cold metal defects.

As a result the desired pouring time has A typical example of this would be a
to be balanced against the minimum Manganese steel mantle. Casting
section thickness in terns of a Rate of weight of 4000 Kg and a pour weight of
rise. 5200 Kg.
Section thickness Rate of Rise
The total height including feeders is
< 4mm > 10cm/sec 1200 mm.
6 to 10 mm > 2cm/sec The section thickness varies from 30
10 to 40 mm > 1cm/sec mm to 110 mm with the 30mm section
> 40 mm > 0.8cm/sec accounting for 0.25 of the total height.

A typical example of these calculations:

Ts = S * (VG) ^0.333 The flow rate then becomes 5200/103

Where or 50Kg /sec.
If the thin section weighs 400 Kg and
Ts = preferred pouring time (sec). is 300mm high then the rate of rise in
S = 1.45 (balanced between 1.6 and 1.3) this section will be:
V = (30 + 110)/2= 70mm.
G = 5200 (Kg. 400Kg/50Kg/sec = 8seconds
300mm/8 sec. = 37 mm/sec
Ts = 103 seconds
Ave rate of rise
Both OK 1200/103 = 12 mm/sec

The gating system should control the rate and direction of flow. This has to fill the cavity
completely before metal solidifies and is measured by flow rate in Kg/sec.

The gating system should reduce turbulence. This will minimize the risk of gas and oxide
entrapment as well as minimizing mould erosion and is measured in cm/sec or velocity.

The gating system should promote ideal temperature gradients. This will give additional
directionality in alloy steels and/or homogenize Mn steels and may be measured by Modulus.

The gating system should provide traps for the separation of inclusions. This promotes
clean steel castings and reduces the need for weld repairs and is measured by profit.

For further information please contact your local FOSECO sales or product manager.

This information sheet was issued by:

Foseco (Foundry Services) Ltd.
No 3 (First floor) Jalan MJ/9, Medan Maju Jaya,
th
7 Mile, Old Klang Road,
46000 Pettling Jaya
Tel: (0060) 3 7781 4925; Fax :3 7781 5010