Riser Design

Ch5
Riser Design
College of Engineering
Mechanical Eng. Dept.
Riser Design
The solidification of most alloys is accompanied by appreciable

volume contraction. The magnitude of this contraction which
gives values for several metals forming alloys of commercial
importance.
The purpose of a feeder head, therefore, is to provide

a reservoir of liquid metal under a pressure head sufficient to
maintain flow into the casting.
Without feeding, the final casting will be subject to shrinkage

defects in the form of major internal cavities, centre line or
filamentary voids
Riser Design
· Liquid shrinkage: The liquid metal loses volume as

it gives up superheat and cools to its solidification
temperature
· Solidification shrinkage: The metal freezes,

changing from a liquid to a higher-density solid. For
pure metals, this contraction will occur at a single
temperature, but for alloys it will take place over
some temperature range or freezing interval
· Solid shrinkage: The solid casting cools from its

solidification temperature to room temperature
The contribution of each one of the three distinct stages of volume
contraction is shown: liquid shrinkage, solidification shrinkage, and solid
contraction
Schematic of the shrinkage of low-carbon steel.

sequence of solidification shrinkage in an iron cube.
(a) Initial liquid
metal.
(a) Initial liquid metal. (b) Solid skin and formation of

shrinkage void. (c) Internal shrinkage. (d) Internal
shrinkage plus dishing. (e) Surface puncture
Methods of
controlling shrinkage
in an iron cube
to reduce riser size
(a) Open-top riser. (b) Open-top riser plus chill. (c) Small
open-top riser plus chill. (d) Insulated riser. (e) Insulated riser
plus chill
Optimum Riser Design
The role of the methods engineer in designing risers can be
stated simply as making sure that risers will provide the feed
metal:
· In the right amount
· At the right place
· At the right time
To this list can be added several other considerations:
· The riser/casting junction should be designed to minimize
riser removal costs
· The number and size of risers should be minimized to

increase mold yield and to reduce production costs
· Riser placement must be chosen so as not to exaggerate

potential problems in a particular casting design
(for example, tendencies toward hot tearing or distortion)
Shrinkage
(volume
contraction)
Riser Location
To determine the correct riser location, the methods engineer
must make use of the concept of directional solidification.
The ability to achieve such directional solidification

will depend on:
· The alloy and its mode of solidification

· The mold medium
· The casting design
Directional and progressive solidification in
a casting equipped with a riser
Feeding distance relationships in steel
plates
(section width
greater than 3T,
where T =
thickness)
Feeding distance
relationships in
steel plates
Feeding distance
relationships
in steel bars
(section width equal

to thickness, T
Effect of chills on feeding distance relationships in steel bars.
Riser necks used
in
iron casting applications
(side view and top view,

respectively).
(a)General type of side

riser.
(b) (b) Side riser for plate
casting.
(c) (c) Top round riser.
Riser Design
The modulus method
The modulus method is based on the concept that the
freezing time of a casting or a casting section can be
approximated by using Chvorinov’s rule
where t is the freezing time of the casting, Vc is

the volume of the casting, Ac is the surface area
of the casting, and k is the constant governed by
metal and mold properties.
The volume-to-area ratio of the casting is
termed the casting modulus, Mc
The freezing times of risers and castings are proportional to

their respective moduli, and if the modulus of the riser, Mr, is
sufficiently greater than the modulus of the casting, Mc,
good feeding will be obtained. In steel, if Mr = 1.2 % Mc,
feeding will be satisfactory.
Mr = 1.2 % Mc
Derivation of cooling modulus values.
(a)Simple shapes,
Simple shapes,
irregular shapes,
Riser configurations and their characteristic values

Riser Design

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Ch5

The solidification of most alloys is accompanied by appreciable

The purpose of a feeder head, therefore, is to provide

Without feeding, the final casting will be subject to shrinkage

· Liquid shrinkage: The liquid metal loses volume as

· Solidification shrinkage: The metal freezes,

· Solid shrinkage: The solid casting cools from its

Schematic of the shrinkage of low-carbon steel.

(a) Initial liquid metal. (b) Solid skin and formation of

· The number and size of risers should be minimized to

· Riser placement must be chosen so as not to exaggerate

The ability to achieve such directional solidification

· The alloy and its mode of solidification

(section width equal

(side view and top view,

(a)General type of side

where t is the freezing time of the casting, Vc is

The freezing times of risers and castings are proportional to

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