Gating & Riser Design 201



Casting quality, yield, and cost are functions of the gating and riser design. This course is a continuation of the concepts introduced in Gating & Riser Design 101. Participants will work on case studies to develop gating and risers to provide clean, sound, and functional castings. A continuation of the fluid flow and solidification principles will serve to guide participants to decision making regarding the quality of castings.

Course emphasis will be placed on hands-on activities, animations, and simulations to enhance understanding of the filling and solidification processes in a foundry. Focus will be on practical examples in iron, steel, aluminum, and copper castings. The goal will be to introduce the participants to the basics of gating and riser design, common industry norms, and troubleshooting.

Learning outcomes

Class participants will learn to:

  • Describe the use of sleeves, hot topping, specialty sands, and the cost vs. benefit of each.
  • Describe sand and chill properties.
  • Measure the influence of sand and chill properties on cooling conditions to positively impact casting quality.
  • Describe fluid flow principles governing the flow of liquid metal.
  • Measure how flow principles governing the flow of liquid metal positively affect casting quality.
  • Identify the use of filters and other hydraulic controls.
  • Describe the influence of process parameter ranges with a fixed tool design on the casting cost and quality.
  • Identify how to accommodate for variations in process parameters while maintaining casting quality.
  • Translate quality requirements to cost implications for castings.
  • Develop a closed-loop tooling performance feedback system.

Course Length

2.0 days

CEU Units

1.20 CEU

Course outline

Module 1: Introduction
Module 2: Thermal Transfer

•    Cooling Curves
•    Solidification Behavior

Module 3: Riser Considerations

•    Shrinkage
•    Riser Calculations
•    Riser Altering Aids

Module 4: Sand and Chill Properties

•    Thermophysical Properties
•    Influence of Sand and Chill Properties

Module 5: Sleeves, Hot Topping, and Specialty Sands

•    Uses
•    Cost vs Benefits

Module 6: Fluid Flow Principles

•    Liquid Metal
•    Use of Filters and Hydraulic Flow Controls

Module 7: Process Parameter Ranges

•    Quantifying Process Parameter Ranges
•    Creating Process Parameter Control Tools
•    Identifying Costly Parameter Variables

Module 8: Closed Loop Feedback System

•    Cost and Quality Objectives
•    Tracking and Communication

Module 9: Conclusion