A study on effects of ceramic foam filter on flow aspect through water modeling experiment

• Published in: China foundry Vol. 14; no. 3; pp. 216 - 225
• Main Authors: Hwang, Ho-Young, Nam, Cheol-Hee, Choi, Young-Sim, Hong, Jun-Ho, Sun, Xun
• Format: Journal Article
• Language: English
• Published: Singapore Springer Singapore 01.05.2017; Foundry Journal Agency; Department of Robotics and Virtual Engineering, Korea University of Science and Technology, Daejeon, 34113, South Korea%Materials Science and Engineering, Kyoto University, Kyoto 606-8501 Japan%Cyber Manufacturing Process Group, Korea Institute of Industrial Technology, Incheon, 21999, South Korea%Shenyang Research Institute of Foundry, Shenyang 110022, China; Cyber Manufacturing Process Group, Korea Institute of Industrial Technology, Incheon, 21999, South Korea
• Subjects: Backup software; Casting (Metal); Celiac disease; ceramic foam filter; sprue; gating system design; sand mold casting; casting defect; Engineering; Engineers; Flow (Dynamics); Machines; Manufacturing; Materials Engineering; Metallic Materials; Overseas Foundry; Oxides; Processes; Runners (Sports); Turbulence (Fluid dynamics); Water; Water wells; A; casting defect; sand mold casting; ceramic foam filter; sprue; TG242/TP391.9; gating system design
• ISSN: 1672-6421; 2365-9459; 1672-6421
• DOI: 10.1007/s41230-017-6108-0

Casting defects that are closely related to entrapped air bubbles and metallic oxides occur very frequently in the sand mold casting process. Many researchers have shown that these defects can be reduced by adopting an appropriate gating system design. However, it is difficult for field engineers to identify a specific gating system that is more appropriate for their products. In this study, we tried to draw a comparison between two gating system designs with and without a ceramic foam filter. The ceramic foam filter was added to the horizontal runner just after the down sprue to prevent air bubble generation and reduce turbulence without a change of gating system design. The water modeling experiment was conducted with four different amounts of the initial volumes of water in the reservoir to verify the effects of initial pouring velocity. The results of the experiment applying the filter showed remarkably changed flow characteristics. The use of the filter was found to convert the flow pattern of water in the desired direction. The ceramic foam filter performed well to reduce flow velocity and stabilize the water stream.The flow pattern without a filter can be improved significantly even with the the use of just a 10 PPI irregular filter. Although the study confirmed that use of the filter may change the flow characteristics, it needs to be noted that the use of the ceramic filter alone cannot solve all the problems caused by a poorly designed gating system.