Faizah Ali

Universitas Jember

Elvira Wahyu Arum Fanani

Universitas Jember

Dwi Wahyu Hardiyanto

Universitas Jember

Imam Rudi Sugara

Universitas Jember

Haidzar Nurdiansyah

Universitas Jember

DOI: https://doi.org/10.19184/rotor.v19i1.60021 

ABSTRACT 

Aluminum sand casting is a manufacturing process widely used in industry due to its low cost and flexibility in product design. This study aims to analyze the gating system design and identify the types of defects that occur in sand-cast aluminum products. The gating system was designed analytically using a 1:2:1 runner ratio with a tapered sprue, including a shrinkage allowance of 13 mm/m, a machining allowance of 1.5 mm, and a draft allowance of 3°. The riser was designed using the Chaine’s method with an exothermic topping and an insulating jacket based on a freezing ratio of 1.64. Measurements of the cast product dimensions revealed deviations ranging from 0–14.29% from the design dimensions, with a deviation pattern characterized by diameter shrinkage, expansion of the center-to-center distance, and uneven wall thickness shrinkage. Identified defects included gas porosity caused by hydrogen gas trapped during solidification, surface roughness due to sand mold shedding, and flash resulting from uneven mold compaction density. A 1:2:1 ratio proved optimal for preventing misruns and cold shuts; however, a degassing process is required to reduce gas porosity in subsequent processes. Although various studies have examined the influence of process parameters on aluminum casting, research on the use of a 1:2:1 gate-to-riser-to-sprue ratio on cast product quality remains limited. Therefore, the novelty of this study lies in the evaluation of the influence of this ratio on defect formation in aluminum castings produced by the sand casting method.

Keywords: gating system, sand casting, aluminum, shrinkage allowance, casting defects

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