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September 11, 2024
1. Casting problem
both inside and outside machining of the holes are porosity.See the defects picture.
2. Casting picture
Casting pictureCasting picture
3. Casting analysis
The product is a deep cavity aluminum alloy case with small size and  geometry + circular feature. Due to the design of gating system, the inside of the product is not fully formed, and the metal liquid reaches the overflow port first that blocks the exhaust. So the trapped air inside the product leads to poor processing.
Casting analysis
4. improving measures
Drop to the depth of runner and cancel existing runner. The runner is redefined and the gate is in the vertical direction, which helps to form the deep cavity firstly. because the gate is blocked by the core, the front end of the water can reach the full wall thickness sequential filling effect. This will discharge the air in the chamber as much as possible. so it achieve the purpose of improvement.
5.Tips
For filling
if casting with deep cavity,it should fill the deep cavity in priority .  fill overflow port first and deep cavity not filled will inevitably lead to air trapped.
 
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Mr. Logan

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