The Importance of the Geometry of the Down Sprue in the Gravity Casting Process

This article presents the results of experiments on the optimization of down sprue geometry in the process of pouring sand molds. Theoretical assumptions and computer simulation tests are presented. The starting point was the theory and experience of gas entrapment caused mainly by a poorly designed gating system and the down sprue. Simulations were performed using Magmasoft software. First, initial studies were carried out to determine how the geometry (mainly the channel cross-section) of the sprue affects the problem, and then a detailed experiment was carried out on the so-called ‘short sprue’ version. The air entrapment process was analyzed, as were the parameters of the liquid alloy flow that passes through the analyzed channels. Nine geometric versions of the sprue were proposed and analyzed, and the results allowed us to conclude which sprue geometry is the best from the point of view of minimization of the gas entrapment problem.