Reducing casting defects in ductile iron castings by optimized pouring system

Main Article Content


Casting simulation technology is an most effective method to provide the predicted information on casting defects such as shrinkage, gas entrapment and non-metalic inclusions. In the study, various version pouring systems have been designed for ductile iron castings in the industrial conditions and a computer-aided design solid modeling program was used in the design of pouring systems for ductile iron castings. Pouring system for ductile iron castings and the gating system ratio of the casting part was selected as 1:3,5:2,5. The flow and solidification of the pouring systems of the casting part was simulated by using magma flow and solidification program. The study clearly shows that the kalpur direct pouring system has revealed that it plays a significant role in preventing non-metallic casting defects in ductile iron castings, such as sand, gas, and slag. In addition, it has been observed in the study that clean parts can be obtained in ductile iron castings with an effective and well-designed pouring system design. The kalpur direct pouring system is recommended to be used in ferrous based castings by FOSECO. The kalpur direct pouring system was used for the first time in ÇİMSATAŞ foundry in the ductile iron castings and the appropriate result was obtained.

Article Details



Campell, J. (2015). Complete Casting Handbook, 2nd ed., Butterworth-Heinemann, Oxford.

Campell, J. (2004). Casting Practice The 10 Rule of Castings, 1st ed., Butterworth-Heinemann, Oxford.

Campbell, J. (2012). Stop pouring, start casting. International Journal of Metalcasting, 6(3), 7-18.

Melendez, A. J., Carlson, K. D., & Beckermann, C. (2010). Modelling of reoxidation inclusion formation in steel sand casting. International Journal of Cast Metals Research, 23(5), 278-288.

Renukananda, K. H., & Ravi, B. (2016). Multi-gate systems in casting process: comparative study of liquid metal and water flow. Materials and Manufacturing Processes, 31(8), 1091-1101.

Brown, J. (Ed.). (2000). Foseco ferrous foundryman's handbook. Butterworth-Heinemann.

Zor, M. M., Yoloğlu, A., Kesim, S., & Tülüce, F. (2022). Pressurized gating system design and optimization in steel castings. Engineering Applications, 1(1), 1-10.

Modaresi, A., Safikhani, A., Noohi, A. M. S., Hamidnezhad, N., & Maki, S. M. (2017). Gating system design and simulation of gray iron casting to eliminate oxide layers caused by turbulence. International Journal of Metalcasting, 11(2), 328-339.

Janiszewski, K., & Kudliński, Z. (2006). The Influence of Non‐Metallic Inclusions Physical State on Effectiveness of the Steel Filtration Process. steel research international, 77(3), 169-176.

Sedex (1999). Foseco Foundry International, the Ceramic Foundry Filter with Foam Structure. Staffordshire, England.

Hsu, F. Y., Jolly, M. R., & Campbell, J. (2009). A multiple-gate runner system for gravity casting. Journal of Materials Processing Technology, 209(17), 5736-5750.

Janiszewski, K. (2013). The slenderness ratio of the filter used in the process of liquid steel filtration as the additional parameter of the filter form. steel research international, 84(3), 288-296.

Ogawa, K., Kanou, S., & Kashihara, S. (2006). Fewer Sand Inclusion Defects by CAE (Vol. 52, No. 158, pp. 1-7). Komatsu Technical Report.

Hrabina, D. (2016). Effective Filtration of Steel Castings, 7th International Ankiros Foundry Congress, 11-13 September, Istanbul, Turkey

Jezierski, J. Dojka, R. & Jenerka, K. (2017). Optimizing Gating System for Steel Castings, 5th International Conference on Modern Manufacturing Technologies in Industrial Engineering, 14-17

Zor, M. M., Kesim, S., Erbakan, B., Tülüce, F., Yoloğlu, A., & Çakır, K. (2022). Direct pouring system design and optimization in steel castings. Engineering Applications, 1(2), 124-131.

Zor, M. M., Kesim, S., Tülüce, F., & Yoloğlu, A. (2022). Reducing casting defects in ductile iron castings by optimized pouring system. Advanced Engineering Days (AED), 5, 25-28.