The Design of the Gating System
Introduction
The gating system or the running system is the series of funnels, pipes and
channels used to guide liquid metal from the ladle into the mould cavity.
Getting the liquid metal out of the crucible and into the mould cavity is a
critical step.
Leaving its design to chance or even to the patternmaker is a risk not to be
recommended.
Literature report has shown that most of the damage is done to castings by
poor filling (gating) design system.
Most castings depend on the action of gravity to effect the
filling action of the mould thus gravity sand casting and gravity
die-casting are important casting processes at the present
time.
Gravity castings have, however, gained a poor reputation
for reliability and quality, simply because their running
systems have in general been badly designed surface
turbulence has led to porosity and cracks, and
unreliability in leak-tightness and mechanical
properties
Types of Mould
An open mould
• cope not required (e.g., wall plaque or
plate which don’t need a well-formed
back surface)
• liquid metal poured directly into the
mould cavity
• skill of foundrymen important
• other viscous and poorly fluid materials
cast in this way include: hydraulic cement
and concrete
A closed mould (Partially
Sectioned)
Filling the mould represents
the greatest of challenges
about 15% investment castings are
scrapped due to having random
inclusions, random porosity,
and misrun – the standard legacy
of a turbulent system
this 15% may rise to 85-95% for
heavy castings (never 100% !!)
and may reduce to 5% for small
castings
design of running system is
crucial
Pressurized vs. Unpressurized Gating Systems in Casting
A gating system controls the flow of molten metal into a mold during casting. The choice
between pressurized, unpressurized and natural systems affects metal velocity, turbulence,
and defect formation.
1. Pressurized Gating System
✅ Characteristics:
•The total cross-sectional area of the runner + gates is smaller than the sprue base.
•Metal flows with high velocity and pressure.
•More turbulent flow, increasing chances of entrapped air or dross.
•Promotes directional solidification.
•Used in high-pressure die casting and small, thin-walled castings.
Advantages:
•Faster mold filling.
•Higher casting yield (less metal lost in runners).
⚠️Disadvantages:
•Increased turbulence → higher porosity & oxidation.
•Requires precise control to avoid defects.
Unpressurized Gating System
✅ Characteristics:
•The total cross-sectional area of the runner + gates is larger than the sprue
base.
•Metal flows at a lower velocity, reducing turbulence.
•Ideal for gravity casting and large castings (e.g., sand casting, investment
casting).
🚀 Advantages:
•Smooth, laminar flow → fewer defects (less air entrapment & oxidation).
•Easier to control filling behavior.
⚠️Disadvantages:
•Slower mold filling → risk of cold shuts in thin sections.
•Lower casting yield (more metal wasted in the gating system).
Having got the metal successfully through the running
system, the question now is,
Will it fill the mould ?
The ability of the molten metal to continue to flow while it
temperature falls (loses heat ) and even at the on set of
solidification is termed fluidity
In casting, Molten metal is expected to fills through all
the interstices of the mould and provides sharp outlines
and faithful reproduction of design details.
Inadequate fluidity may be a factor in short run castings or
In terms of casting alloys, the fluidity is, thus, defined as the
maximum distance Lf to which the metal will flow in a
standard mould before solidification.
The failure of a liquid to fill the mould cavity results not
from high viscosity but from premature solidification.
Thermal conditions and mode of solidification are thus the
critical factors with respect to cessation of flow. The concept
of fluidity takes these aspects into account.
Maximum Fluidity Length Vs. Continuous Fluidity
Length
In a long mould, the metal will
continue to flow until stopped at
distance Lf by solidification. This
is the maximum fluidity length
(or simply the fluidity) Lf of the
metal.
In a short mould, the
migration of the growing choke
may reach the end of the channel
before the channel is closed.
The flowing metal will re-melt the
choke completely and the flow
will continue uninterrupted.
This is the continuous fluidity
length or the critical fluidity, Lc of
the metal.
Measurement of fluidity
Fuidity is a measure of the maximum distance covered by molten
metal in standardized systems of enclosed channels before cessation
of flow
Typical Test Methods
1.Straight flow channel
2. Spiral test
3. Standardized fluidity test
Factors Controlling Fluidity
1.Composition and mode of solidification
• Long- and short-freezing-range alloys
2. Liquid velocity
3. Solidification time
• Modulus • Heat transfer coefficient • Superheat • Latent
heat • Mould temperature
4. Surface tension
Mode of Solidification of Different Metals
Short/Skin Freezing Range Alloys
Short Freezing Range Alloys
•These alloys solidify quickly over a narrow temperature range, meaning they transition
from liquid to solid almost instantly.
•They are less prone to segregation and hot tearing.
•Example: Eutectic alloys (e.g., eutectic aluminium-silicon alloys like Al-Si 12%).
Skin Freezing in Alloys
•This refers to a process where a solid skin forms quickly at the mold surface during
casting, while the interior remains liquid.
•It occurs in alloys with a short freezing range or low thermal conductivity.
•Can influence casting defects and shrinkage.
Features Short/Skin
Freezing Range Alloys
Solidifies at a single or narrow-range of
temperature
Planar front of solidification
Solidification starts from the mould wall
and grows inside
The point of solidification migrates
downstream
Solidification needs to be 100 %
complete at one location for flow to
stop
Total fluidity length for these materials:
Lf = V t f
where, V = velocity of flow (assuming constant !!) t f = time for solidification
Long freezing range
•alloys
Freezes over a wide range of temperatures
• Dendritic mode of solidification
• The liquid metal transforms into a slurry of
dendritic crystals and starts to offer
resistance to the flow of liquid metal
• At some point of solidification (in the range
of 20 – 50 % solid), the flow ceases.
• Total fluidity length for these materials: Lf
Lf = x V t f
x = fraction of solids in melt when
solidification ceases, which depends
The velocity is explicit in the equations for fluidity.
Thus, fluidity increases linearly with an increase in velocity. However,
increasing fluidity by increasing liquid velocity is a mistake.
Thus, in general, up to small head heights of the order of 100 mm fluidity
can be raised linearly with an increase in speed of flow.
However, further increases in speed appear to be counterproductive, if
castings relatively free from defects are required.
FEEDING MECHANISM DURING CASTING
Introduction
Casting is one of the oldest manufacturing processes used for shaping metals
and alloys into desired forms. During the solidification of a casting, shrinkage
occurs due to thermal contraction. If not properly managed, shrinkage can lead
to defects such as porosity, voids, and cracks. To compensate for this shrinkage,
a feeding mechanism is employed, ensuring that additional molten metal is
available to fill the voids created during solidification. The effectiveness of a
feeding system directly influences the quality and integrity of the final casting
Importance of Feeding Mechanism
The primary objectives of a feeding mechanism in casting include:
1.Compensating for Solidification Shrinkage: Preventing defects
caused by volume contraction during phase transition from liquid to
solid.
2.Enhancing Mechanical Properties: Ensuring uniform microstructure
and preventing weak spots.
3.Improving Surface Finish: Avoiding shrinkage cavities that can affect
aesthetic and functional properties.
4.Reducing Defects: Minimizing issues like porosity, micro-shrinkage,
and hot tears.
5.Optimizing Yield: Enhancing material utilization and minimizing
wastage.
Types of Feeding Systems
The feeding mechanism in casting involves different components designed to
deliver additional molten metal to the casting. The main types include:
1. Risers (Feeders)
Risers are reservoirs of molten metal that provide additional material as the casting
solidifies. They serve as the main feeding source and can be categorized into:
•Open Risers: Exposed to the atmosphere and easy to remove, but prone to
oxidation.
•Blind Risers: Enclosed within the mold cavity, reducing oxidation and improving
feeding efficiency.
•Side Risers: Located at the sides of the casting, suitable for feeding thin sections.
•Top Risers: Positioned on top of the casting, ideal for feeding thick sections.
•Necked Risers: Designed with a narrow connection to ensure easy removal post-
solidification.
2. Chills
Chills are metallic inserts placed within the mold to control solidification patterns.
They are classified into:
•External Chills: Positioned outside the mold cavity to accelerate cooling in specific
areas.
•Internal Chills: Embedded within the mold to enhance localized cooling.
3. Gating System Contribution
The gating system plays an indirect role in feeding by directing molten metal
efficiently into the mold. Properly designed gates, runners, and sprues help
maintain adequate feeding pressure.
Design Considerations for an Efficient Feeding System
To ensure an effective feeding mechanism, several factors must be considered:
1. Feeder Size and Shape
•Feeders must be large enough to supply adequate molten metal.
•The shape should promote directional solidification, allowing molten metal to
flow from the feeder to the casting.
2. Feeder Placement
•Feeders should be positioned at the last freezing areas to ensure proper
compensation for shrinkage.
•Multiple feeders may be required for complex castings.
. Feeder Insulation
•Insulating sleeves can prolong feeder solidification time, improving efficiency.
•Exothermic materials can be used to maintain feeder temperature for longer
durations.
4. Directional Solidification
•Solidification should progress from thin to thick sections, ensuring that feeders
remain liquid for longer.
•Chills and risers help achieve controlled solidification.
Techniques to Improve Feeding Efficiency
Several methods enhance the effectiveness of feeding mechanisms:
1. Use of Computational Modeling
Advanced simulation software predicts shrinkage patterns and optimizes feeder
design.
2. Exothermic and Insulating Materials
Adding exothermic compounds or insulating sleeves around feeders enhances
heat retention and feeding efficiency.
3. Optimized Pouring Temperature
Maintaining an appropriate pouring temperature ensures proper metal flow and
feeding performance.
4. Directional Solidification Strategies
Using chills and proper riser placement encourages a controlled
solidification sequence.
5. Hot Topping
A layer of exothermic material on top of the riser prolongs its
solidification, improving feeding effectiveness.
Common Defects Due to Poor Feeding
Inadequate feeding can lead to several casting defects, including:
1.Shrinkage Cavities: Voids formed due to insufficient feeding metal.
2.Porosity: Gas entrapment exacerbated by improper feeding.
3.Hot Tears: Cracks resulting from high thermal stress due to uneven
solidification.
4.Misruns: Incomplete mold filling due to inadequate molten metal.
5.Cold Shuts: Weak joints caused by premature solidification of molten streams.
