Investigation of porosity in Al casting

Abstract Porosity is one of the serious problems observed in foundries. In the present study pure aluminium (99.85%) is used as a cast material. For both simulation and experimental work, it has been seen that due to the pouring temperature, pouring time and different types of gating system design, porosity in the casting is greatly influenced. Here optimization of pouring temperature, pouring time and gating design is done by using Auto-CAST simulation technique. Finally, experimental results are validated with Auto-CAST simulation results and improvements are suggested in terms of optimisation of gating system by modelling and simulation technique. Non-destructive method of testing like dye-penetrant test has been used for checking the surface defects and ultrosonic method of testing has been used for evaluating the presence of subsurface defects.