Numerical and experimental determination of the feeding distance of aluminum alloys in gravity die casting using an optimized riser shape

A finite difference thermal model was utilized to analyze the solidification process and to predict the maximum feeding distance in gravity die casting of aluminum alloys with an optimal riser shape. Predictions are verified experimentally for both pure aluminum and Al-12\% Si alloy. The experimental maximum feeding distance for castings made from Al-12\% Si alloy in gravity die castings was found to be 10 times the casting thickness, compared to 9.1 times the casting thickness from numerical predictions. For pure aluminum, the experimental maximum feeding distance was 7 times the casting thickness, compared to 6.2 times the casting thickness from numerical analysis.