Abstract
Abstract: This research deals with the elimination of defects in aluminium alloy castings and enhancement in the casting yield and quality. The main intention of the work is to improve the quality of a cast component using Computer Aided Casting Simulation Software. SOLID Cast simulation software is used for simulating the solidification process of casting and visualizing outputs showing possible problematic areas or defects which may occur in the cast product. Plate Castings of aluminium alloy - LM 24 are produced with different designs of gating systems and tested for defects like porosity using Archimedes immersion Technique and also Radiographic testing is used to check the quality of the castings. The produced castings are observed to be sound, and the results obtained are in agreement with the simulation results. Hence it is verified that solidification simulation helps in improving the quality of castings without any shop-floor trails. Casting yield and percentage porosity values are determined for 12 castings produced with different gating systems. The best results are observed to be produced by the castings having a 1-Ingate system in horizontal or lateral positions.
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