Setting of low pressure casting parameters for aluminum alloy castings

Low-pressure casting involves six key stages: liquid lifting, filling, pressurization, holding pressure, exhaust and cooling, and mold cleaning. Each of these stages plays a crucial role in determining 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" also denotes the filling pressure, and "p" indicates the supercharging pressure. Time parameters are labeled as t₁ (liquid lifting time), t₂ (filling time), t₃ (pressurization time), t₄ (holding time), and t₅ (cooling and exhaust time). The variable "h" refers to the height of the molten metal level rising from the tank or lift gate. During the filling stage, the liquid surface typically rises 200 to 300 mm above the top of the mold. Δh represents the drop in the liquid level after each cycle, which affects the pressure compensation during filling and may require adjustments in both the filling pressure (p-fill) and the lifting time (Δt), although Δt is usually negligible. The image below shows the pressure curve for reference: **First, the principle of setting low-pressure casting process parameters** (1) Selecting the right liquid lifting and filling times helps shorten the production cycle while ensuring that the aluminum melt doesn't splash during the rise. The liquid lifting speed is typically maintained between 10–15 cm/s, and the filling must be done steadily to avoid turbulence. Proper venting of the casting cavity is essential to prevent back pressure caused by rapid filling. When using sand cores, it's important to consider their structural integrity to avoid breakage. Therefore, the filling speed is usually kept between 2–4 cm/s. During the pressurization phase, the supercharging speed is slightly faster than during filling. The supercharging pressure is generally 0.5 to 1 times higher than the filling pressure. The rate at which pressure increases is critical to maintaining consistent and stable conditions throughout the process. For more detailed information on parameter settings and practical examples, please refer to the attached document.

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