A novel nonlinear pressurization method for counter-gravity casting of cross-sectional mutation structures

Abstract In order to ensure the filling integrity of complex counter-gravity casting and improve metallurgical quality, it is necessary to shorten the filling time while avoiding air entrainments. To address this contradiction, a novel nonlinear pressurization method was proposed in this study. Through systematically analyzing the relationship between critical gating velocity and stable filling height, a criterion for iterative calculation of nonlinear pressurization curve was established, and an empirical expression between nonlinear pressurizing speed and the filling height was obtained. Based on the empirical expression, a nonlinear pressurization curve can be designed according to the casting structures and initial pressurizing speeds. The above nonlinear pressure curve design method was validated through water filling experiments. It was proved that the nonlinear pressure curve can shorten the filling time while avoiding air entrainments. It provides important processing control method for improving the low-pressure casting performance of complex castings.