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Chapter from the book Recent Trends in Processing and Degradation of Aluminium
Alloys
Downloaded from: http://www.intechopen.com/books/recent-trends-in-processing-
and-degradation-of-aluminium-alloys
1. Introduction
Counter-gravity casting, also called vacuum casting, is a mould filling technique in which low
pressure created inside a mould cavity, causes prevailing atmospheric pressure on the melt
surface to bring about an upward or counter-gravity movement of the melt into the mould
cavity. The process was patented in 1972 by Hitchiner Manufacturing (Lessiter & Kotzin, 2002)
and different variants of the process had evolved over the years. Greanias & Mercer (1989)
reported a novel valve system that could potentially increase throughput by allowing mould
disengagement prior to solidification while Li et al (2007) have developed a multifunctional
system aimed at aggregating different variations of the technology into a single equipment.
The unique mould filling approach of the countergravity casting technique confers on it a
set of unique advantages related to casting economics, defects elimination and attainment of
net-shape in cast products. Such desirous attributes has ensured the growing importance of
the technology, especially in power and automotive applications. A testament to the rising
profile of this casting technique is its adoption in the production of a range of parts such as
compressor wheels for turbo-chargers (TurboTech, 2011), automotive exhaust manifolds
(Chandley, 1999) and a high-volume production (130,000 units/day) automotive engine
Rocker Arm (Lessiter, 2000).
The growing importance of this casting technique in some metal casting sectors
notwithstanding, there is scant awareness and interest in many mainstream casting spheres.
This chapter thus seeks to present a technology overview of the countergravity casting
technique. The shortcomings of conventional processes are highlighted alongside the unique
advantages of the countergravity technique. Challenges of the countergravity technique are
also presented with discussion of efforts and prospects for their redemption.
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4 Recent Trends in Processing and Degradation of Aluminium Alloys
Fig. 2. Down sprue, with conical base (a) is integrated with the rest of the investment mould
tree (c). The assemble rests inside the conical depression of the lock-nut (b)
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Aluminium Countergravity Casting Potentials and Challenges 5
The otherwise solid investment mould is made permeable by a single opening at its apex.
This opening effectively connects the mould cavity with the interior space of the moulding
flask, making it an extension of the moulding flask and enabling its evacuation along with
the rest of the flask. The flask lid hosts the casting valve, a connecting hose to the vacuum
system and lid locking mechanism. The electrical resistance furnace melts the aluminium
charge, usually by a superheat of about 40 C above the melting temperature (660 C) of
aluminium to reduce melt viscosity and ease melt up-flow into the mould. During
countergravity casting, the moulding flask with the mould assembly inside, is placed on the
furnace lid with the down-sprue poking through a hole in the furnace lid.
The vacuum system evacuates the moulding flask and the ensuing low pressure thus
created causes ambient atmospheric pressure on the melt to push up the molten metal, up
inside the mould. See figure 3.
Fig. 3. The evacuation of the moulding flask (a) also evacuates the investment mould cavity.
This causes molten aluminium to rise up into the mould cavity (b)
Apart from investment material, the mould could be a metal mould or a ceramic mould. The
vacuum system is calibrated so that just the right volume of melt flows inside the mould for
a period long enough for the melt to solidify. The vacuum is released after allowing enough
time for melt solidification in the mould cavity. This allows un-solidified melt along the
sprue length to be flow back into the furnace. The illustration in figure 4 shows the vacuum
being maintained until the cavity is completely filled. Vacuum pressure is then released
causing un-solidified melt in the sprue to flow back into the furnace
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6 Recent Trends in Processing and Degradation of Aluminium Alloys
Fig. 4. The vacuum is maintained until the cavity is completely filled. Vacuum pressure is
released causing un-solidified melt to flow back into the furnace
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Aluminium Countergravity Casting Potentials and Challenges 7
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8 Recent Trends in Processing and Degradation of Aluminium Alloys
3.3 Shrinkage
Shrinkage is the natural consequence of liquid to solid transformation of the melt during
cooling and is common in most metals. Shrinkage is particularly severe in aluminium alloys.
In aluminium alloys, the volumetric shrinkage ranges from 3.5% to 8% (Kaufman and Rooy,
2004). This manifests as shrinkage cavities in larger portions of the casting.
This is often counteracted by strategic placement of risers. Figure 7 shows the typical
appearance of volumetric shrinkage defect in an aluminium section.
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Aluminium Countergravity Casting Potentials and Challenges 9
turbulent cavity-fill (Jorstad, 2003). The process of air melting and pouring also inevitably
introduces oxides, formed during melting, into the cast product. Significant inclusions
segregation at grain boundaries are thus very common with gravity assisted sand casting.
4.4 Economical
Countergravity technique significantly decreases the amount of gates that must be re-melted
(Flemings et al, 1997). This was actually one of the original goals of the countergravity
technique at its inception. Fettling time and costs are reduced while high quality melt is
judiciously used.
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10 Recent Trends in Processing and Degradation of Aluminium Alloys
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Aluminium Countergravity Casting Potentials and Challenges 11
Fig. 10. Ceramic mould at 400 magnification shows heavy segregation of impurities at the
grain boundaries
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12 Recent Trends in Processing and Degradation of Aluminium Alloys
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Aluminium Countergravity Casting Potentials and Challenges 13
Composites (MMC) which can be cast into complex, intricate geometries. These materials
have found applications in diverse fields, from high quality reflective mirrors to optical
and laser equipment (OFallon Casting, 2009). There has been increased interest in the use
of cast aluminium/silicon carbide MMC for optoelectronics packaging due to its
compatible coefficient of thermal expansion, high thermal conductivity, and potential to
produce parts at low cost (Berenberg, 2003). In ring laser gyros, these MMCs are
displacing traditional favourites like beryllium and stainless steel in the production of
dimensionally stable mirrors that can withstand extreme thermal cycling (Mohn and
Vukobratovich, 1988).
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14 Recent Trends in Processing and Degradation of Aluminium Alloys
point of the sprue on the mould. These non-ideal, but very real instances may require a
more interactive vacuum system, wherein pressure feedback is used to constantly adjust the
flask vacuum pressure.
Fig. 12. Premature solidification of melt inside the sprue due to inadequate pre-heat
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Aluminium Countergravity Casting Potentials and Challenges 15
The possibility of more economical use of the melt is good for the bottom line of foundry
operation and was actually the original goal of the countergravity technique. This has
motivated a growing list of companies and industrial sector to adopt the technology.
The combination of precision near net shape and strength has resulted in countergravity die
casting being used to produce parts formerly made of steel that required a significant
amount of secondary machining (Aurora Metals LLC, 2009).
Net shape casting, particularly for thin sections is easily achievable in countergravity
casting. Countergravity cast part may have walls as thin as 0.5 mm (National Institute of
Industrial Research, 2005).
In order to make the benefits of this casting technique more accessible, low-cost
countergravity equipment have been developed. A low-cost design developed by the
authors is presented in figure 13.
The design utilizes a simplified vacuum control system and manual positioning of mould
and moulding flask. Such low cost alternatives would be invaluable for small scale
operations.
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16 Recent Trends in Processing and Degradation of Aluminium Alloys
portions of the melt in the down sprue to be returned to the furnace whilst keeping the
portion delimited by the valve in the moulding flask.
Vacuum control in countergravity casting has benefited significantly from advances in
control technology and instrumentation. Li et al (2008) demonstrated a pressure control
system based on fuzzy-PID control and a digital valve system and achieved pressure error
of less than 0.3 KPa. Other workers such as Khader et al (2008) have carried out extensive
system modelling of the countergravity casting machine with the goal of developing an
automatic controller for control of machine operation.
8. Conclusion
Metal casting is several millennia old, and yet it continues to evolve both in areas of
applications and in the technologies of implementation. The increasing relevance of
aluminium alloys in modern technology, from power applications to consumer products,
makes it imperative to seek better, more cost-effective production routes.
The countergravity casting technique is an ingenious method for production of aluminium
parts. The numerous permutations and mutations of this technique over the last four
decades is a testament to its feasibility and flexibility; and a recognition of its inherent
advantages. Aluminium alloy castings stand to benefit immensely from the unique
attributes of the countergravity technique because the goals of net-shape casting and
superior mechanical properties are truly achievable via this method.
9. References
Alexander, D. (2002). High-Performance Handling Handbook. MotorBooks International,
ISBN 978-0760309483, Osceola, Wisconsin
Aurora Metals. (2009). Vacuum Cast Impellers. March 12th 2011, Available from:
< http://www.aurorametals.com/vc.htm>
Berenberg, B. (2003). Metal Matrix Composites Advance Optoelectronics Package Design. In:
High Performance Composites, 20th May, 2011, Available from:
< http://www.compositesworld.com/articles/metal-matrix-composites-advance-
optoelectronics-package-design>
Bray, R. (1989). Aluminium casting process finds new applications; developments in the
Cosworth Process have spread its application to such fields as the aerospace and
defence industries. Modern Casting, 20th May 2011, Available from;
< http://www.highbeam.com/doc/1G1-8230613.html>
Chandley, G.D.; Redemske, J.A.; Johnson, J.N.; Shah, R.C. & Mikkola, P.H.(1997). Counter-
Gravity Casting Process for Making Thinwall Steel Exhaust Manifolds Society of
Automotive Engineers (SAE), Technical Papers, March 3rd 2011., Available from:
< http://papers.sae.org/970920/>
Chandley, G.D. (1999). Use of vacuum for counter-gravity casting of metals. Materials
Research Innovations, Vol. 1999, No. 3, pp 14-23.
Druschitz, A.P & Fitzgerald, D.C. (2000). Lightweight Iron and Steel Castings for
Automotive Applications. Proceedings of Society of Automotive Engineers (SAE) 2000
World Congress, ISSN 0148-7191, Detroit Michigan, March, 2000
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Aluminium Countergravity Casting Potentials and Challenges 17
Flemings, M.; Apelian, D.; Bertram, D.; Hayden, W.; Mikkola, P. & Piwonka, T.S. (1997).
World Technology Evaluation Centre Report on Advanced Casting Technologies in Japan
and Europe. American Foundrymens Society (AFS), ISBN 1-883712-45-9
Greanias, A.C. & Mercer, J.B. (1989). Vacuum countergravity casting apparatus and method
with backflow valve, In: United States Patent 4862945, March 3rd 2011, Available
from :< http://www.freepatentsonline.com/4862945.html>
Griffiths, W.D.; Cox, M.; Campbell, J & Scholl, G. (2007). Influence of counter gravity mould
filling on the reproducibility of mechanical properties of a low alloy steel. Materials
Science and Technology, Vol. 23, No. 2, pp 137-144, ISSN 0267-0836
Jie, W.Q.; Li, X.L. & Hao, Q.T. (2009). Counter-Gravity Casting Equipment and Technologies
for Thin-Walled Al-Alloy Parts in Resin Sand Moulds. Materials Science Forum. Vols.
618-619 (2009), pp 585-589
Jorstad, J.L. (2003). High Integrity Die casting Process Variations, Proceedings of
International Conference on Structural Aluminium Casting, Orlando Florida,
November, 2003
Kaufman, G.J. & Rooy, E.L. (2004). Aluminium Alloy Castings Properties, Processes, and
Applications. ASM International, ISBN 0-87170-803-5, Ohio.
Key to Metals (2010). Aluminium and Aluminium Alloys Casting Problems. March 6th 2011,
Available from: < http://www.keytometals.com/Article83.htm>
Khader, A. M.; Abdelrahman, M. A.; Carnal, C.C. & Deabes, W. A. (2008). Modelling and
Control of a Counter-Gravity Casting Machine. Proceedings of 2008 American Control
Conference, Seattle Washington, June 2008
Lessiter, M.J. & Kotzin, E.L. (2002). Timeline of Casting Technology. Engineered Casting
Solutions, Summer 2002, pp 76-80.
Lessiter, M.J. (2000). Engineered Cast Solutions for the Automotive Industry. Engineered
Casting Solutions, Fall 2000, pp 37-40.
Li, X.; Hao, Q.; Jie, W. & Zhou, Y. (2008). Development of pressure control system in counter
gravity casting for large thin-walled A357 aluminium alloy components.
Transactions of Nonferrous Metals Society of China, Vol. 18, No. 4, pp 847-851
Li, X.; Hao, Q.; Li, Q. & Jie, W. (2007). Study on Technology of Multifunction Counter
Gravity Casting Equipment. Foundry Technology, Vol. 07, No. 014,
Mohn, W.R. & Vukobratovich, D. 1988. Recent applications of metal matrix composites in
precision instruments and optical systems. Optical Engineering, Vol. 27, No. 2, pp
90-98
National Institute of Industrial Research (NIIR) Board of Consultants & Engineers. (2005).
The Complete Book on Ferrous, Non-Ferrous Metals with Casting and Forging
Technology. National Institute of Industrial Research, ISBN: 8186623949, New
Delhi
OFallon Casting. (2009). Silicon Carbide Metal Matrix Composite Alloys (SiC MMC),
March 12th 2011, Available from:
< http://www.ofalloncasting.com/MetalMatrix.html>
Spada, A.T. (1998). Hitchiner Manufacturing Co. Turning the Casting World Upside
Down. Modern Casting, Vol. 88, No. 7, pp 39-43
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18 Recent Trends in Processing and Degradation of Aluminium Alloys
TurboTech Precision Products Ltd. (2011). Aluminium Compressor Wheel Castings for
Turbochargers, March 3rd 2011, Available from:
< http://www.turbotech.co.uk/manufacturing-process.htm>
Waterman, P.J. (2010). Understanding Core-Gas Defects Flow-3D software helps trace,
predict and avoid bubble streams in metal castings. In: Desktop Engineering, Design
Engineering and Technology Magazine, March 6th 2011, Available from:
< http://www.deskeng.com/articles/aaaype.htm>
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Recent Trends in Processing and Degradation of Aluminium Alloys
Edited by Prof. Zaki Ahmad
ISBN 978-953-307-734-5
Hard cover, 516 pages
Publisher InTech
Published online 21, November, 2011
Published in print edition November, 2011
In the recent decade a quantum leap has been made in production of aluminum alloys and new techniques of
casting, forming, welding and surface modification have been evolved to improve the structural integrity of
aluminum alloys. This book covers the essential need for the industrial and academic communities for update
information. It would also be useful for entrepreneurs technocrats and all those interested in the production
and the application of aluminum alloys and strategic structures. It would also help the instructors at senior and
graduate level to support their text.
How to reference
In order to correctly reference this scholarly work, feel free to copy and paste the following:
Bolaji Aremo and Mosobalaje O. Adeoye (2011). Aluminium Countergravity Casting Potentials and
Challenges, Recent Trends in Processing and Degradation of Aluminium Alloys, Prof. Zaki Ahmad (Ed.), ISBN:
978-953-307-734-5, InTech, Available from: http://www.intechopen.com/books/recent-trends-in-processing-
and-degradation-of-aluminium-alloys/aluminium-countergravity-casting-potentials-and-challenges