Setting of low pressure casting parameters for aluminum alloy castings

Low-pressure casting involves six main stages: liquid lifting, filling, pressurization, holding pressure, exhaust and cooling, and mold cleaning. Each of these stages requires precise parameter settings, as they directly influence the final product quality and overall production cycle. The diagram illustrates the pressure curve for the EG01T cylinder head during the casting process. In the figure, "p" represents the hydraulic pressure in liters, "p_filling" refers to the filling pressure, and "p_supercharge" is the supercharging pressure. Time parameters include t₁ for liquid lifting, t₂ for filling time, t₃ for pressurization, t₄ for holding time, and t₅ for cooling after exhaust. The height "h" corresponds to the rise of the molten metal level during lifting, typically reaching a distance of 200–300 mm above the tank or lift gate. During the filling stage, h represents the liquid surface height, and Δh indicates the drop in liquid level after each cycle. This drop may require additional pressure compensation (p_fill) and an adjustment in lift time (Δt), which is usually negligible. The image below provides a visual representation of the pressure curve: **First, understanding the principle of setting low-pressure casting parameters** (1) Choosing the right liquid lifting and filling times is essential for improving production efficiency while ensuring that the molten aluminum does not splash during the process. The liquid lifting speed is typically controlled between 10–15 cm/s, and the filling speed must be carefully managed to maintain stability. Proper venting of the casting cavity is important to avoid back pressure caused by excessive filling speed. When using sand cores, care must also be taken to prevent damage from the impact of the molten metal. Generally, the filling speed is kept around 2–4 cm/s. During the pressurization phase, the supercharging speed is slightly higher than during filling, and the supercharging pressure is usually 0.5 to 1 times the filling pressure. The rate of pressure increase should be adjusted based on the specific requirements of the casting. For more detailed information, please refer to the attached document.

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