A Review on Elimination of Defects in Gravity Die Cast Al-Alloy Casting Using Autocast Simulation

The paper deals with the elimination of defects in aluminum alloy casting produced by gravity die casting process. The main intention is to investigate the defects and improve quality of a gravity die cast component using Autocast simulation software. The defects in the component are identified to be solidification shrinkage, cracks, unfilled riser and incomplete mould cavity. The reasons of defects are analyzed as either improper selection of process parameter or improper design of gating and risering system. The Autocast software for casting simulation is helpful to visualize mould filling, solidification, cooling and to predict the location of internal defect in casting such as shrinkage porosity, sand inclusions and cold shuts. It can be used for troubleshooting existing casting and to develop new casting without shop floor trials. The die is modified accordingly with the simulation results and metal is poured into it. The casting produced are observed and found to have no defects.