Editing Metal casting (section)

===The gating system===<!-- [[Runner (casting)]] and [[Gate (casting)]] redirect here -->
[[File:Casting gating system.svg|class=skin-invert-image|thumb|right|400px|A simple gating system for a horizontal parting mold.]]
{{See also|Sprue (manufacturing)}}

The gating system serves many purposes, the most important being conveying the liquid material to the mold, but also controlling shrinkage, the speed of the liquid, turbulence, and trapping [[dross]]. The gates are usually attached to the thickest part of the casting to assist in controlling shrinkage. In especially large castings multiple gates or runners may be required to introduce metal to more than one point in the mold cavity. The speed of the material is important because if the material is traveling too slowly it can cool before completely filling, leading to misruns and cold shuts. If the material is moving too fast then the liquid material can erode the mold and contaminate the final casting. The shape and length of the gating system can also control how quickly the material cools; short round or square channels minimize heat loss.<ref name="degarmo284">{{Harvnb|Degarmo|Black|Kohser|2003|p=284}}</ref>

The gating system may be designed to minimize turbulence, depending on the material being cast. For example, steel, cast iron, and most copper alloys are turbulent insensitive, but aluminium and magnesium alloys are turbulent sensitive. The turbulent insensitive materials usually have a short and open gating system to fill the mold as quickly as possible. However, for turbulent sensitive materials short sprues are used to minimize the distance the material must fall when entering the mold. Rectangular pouring cups and tapered sprues are used to prevent the formation of a vortex as the material flows into the mold; these vortices tend to suck gas and oxides into the mold. A large sprue well is used to dissipate the kinetic energy of the liquid material as it falls down the sprue, decreasing turbulence. The ''choke'', which is the smallest cross-sectional area in the gating system used to control flow, can be placed near the sprue well to slow down and smooth out the flow. Note that on some molds the choke is still placed on the gates to make separation of the part easier, but induces extreme turbulence.<ref name="degarmo285">{{Harvnb|Degarmo|Black|Kohser|2003|p=285}}</ref> The gates are usually attached to the bottom of the casting to minimize turbulence and splashing.<ref name="degarmo284"/>

The gating system may also be designed to trap dross. One method is to take advantage of the fact that some dross has a lower density than the base material so it floats to the top of the gating system. Therefore, long flat runners with gates that exit from the bottom of the runners can trap dross in the runners; note that long flat runners will cool the material more rapidly than round or square runners. For materials where the dross is a similar density to the base material, such as aluminium, ''runner extensions'' and ''runner wells'' can be advantageous. These take advantage of the fact that the dross is usually located at the beginning of the pour, therefore the runner is extended past the last gate(s) and the contaminates are contained in the wells. Screens or filters may also be used to trap contaminates.<ref name="degarmo285"/>

It is important to keep the size of the gating system small, because it all must be cut from the casting and remelted to be reused. The efficiency, or ''{{visible anchor|yield}}'', of a casting system can be calculated by dividing the weight of the casting by the weight of the metal poured. Therefore, the higher the number the more efficient the gating system/risers.<ref name="degarmo287"/>