Experimental Analysis of Gating Desing for Rapid Investment Casting of Aluminium Dies
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Keywords:
Rapid Investment Casting, Die Development, Aluminum, Gating System, Surface Roughness, Dimensional AccuracyAbstract
This study examined how three different gating systems impacted the quality of aluminum dies
developed through rapid investment casting. Gating System A, which featured a vertical setup with two
ingates and effective venting, achieved a surface roughness of 3.2 μm, a minimal dimensional deviation
of ±0.4 mm, and the highest hardness value of 35 HRB, demonstrating better performance. It also had the
fewest surface defects, displaying an excellent finish with no signs of porosity or cold shut. Gating
System C used the bottom fill technique and lacked a top ingate, resulting in moderate outcomes: a
surface roughness of 4.5 μm, a dimensional deviation of ±0.8 mm, and a hardness of 31 HRB. Minor
defects such as localized shrinkage marks and waviness were observed. Conversely, Gating System B
proved to be the least effective, as it used only a top ingate and had improper venting. It had the lowest
hardness at 28 HRB, with a surface roughness of 6.5 μm, and the highest dimensional error of ±1.2 mm.
It also exhibited many surface defects, including air entrapments, cold shuts, and uneven surfaces caused
by turbulent flow and insufficient feeding. These findings underscore the importance of optimizing gating
design to achieve desirable mechanical properties, accurate dimensions, and smooth surface finishes in
the production of aluminum dies via rapid investment casting.
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