Moreover, the formation of different casting defects is directly related to fluid flow phenomenon in the mold cavity during filling and the rate of cooling which affects the microstructure and the mechanical properties of the product. As the production of sound castings without any defect is always the main objective of a foundry, proper and intelligent methodings are suggested to improve the aesthetic look of the defect-free casting, which, in turn, will reduce fettling cost and rework. Improper gating design/ratio causes infilling, blow hole, shrinkage and cold shut defects. Method design is one of the critical areas which directly affect the casting quality. In the present scenario, where the selling price of products, especially Ductile Iron products, are not increasing so rapidly, the only way to cope up with the increasing energy and raw material cost is to reduce the production cost, which may involve proper and intelligent method design, implementation of software, and following some good practices in the foundry management.
The cost of Energy, labour and raw materials increases day by day, which reduces the net profit margin of a Foundry. Over 50% of this energy is not utilized for the final casting itself, but is used for gating and risering systems. Physical laws determine an average energy input of 2,000 kWh per metric ton of final casting product. Melting and solidifying metals require a high amount of energy. The costs for energy and materials in foundries are 40% of the total cost.
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