Metallurgical and Materials Transactions B

, Volume 46, Issue 1, pp 337–344 | Cite as

Observation of the Mold-Filling Process of a Large Hydro-Turbine Guide Vane Casting

  • Jinwu KangEmail author
  • Haimin Long
  • Yongjie Li
  • Rui You
  • Xiaokun Hao
  • Gang Nie
  • Tianjiao Wang
  • Chengchun Zhang


The mold-filling process has a determining effect on the quality of castings, and it has always been a hot but difficult research topic. The authors developed a wireless monitoring system for the mold-filling process of castings based on a contact time method and an observation system based on heat-resistant high-speed cameras. By using these two systems, the filling process of a turbine guide vane casting with a stepped gating system was investigated. The filling profile of the casting was recorded, and the filling time of nine typical positions was acquired. These results show that at the beginning, the liquid steel flowed out from the top ingate, which was designed to be the last to fill. The numerical simulation of the filling of the guide vane was performed, and the outflow from the top ingate were predicted. Finally, the gating system of the casting was improved with enlarged sprue. The new design features bigger sprue to ingate ratio; therefore, it could avoid the overflow from the top ingate and realize stable filling.


Riser Filling Time Monitoring Point Guide Vane Filling Process 
These keywords were added by machine and not by the authors. This process is experimental and the keywords may be updated as the learning algorithm improves.



The project is funded by National Science and Technology Major Project of the Ministry of Science and Technology of China under Project No. 2012ZX04012011 and National Basic Research Program of China (No. 2011CB012900).

Supplementary material

Supplementary material 1 (WMV 8544 kb)


  1. 1.
    A.S. Usmani, J.T. Cross, and R.W. Lewis: Int. J. Numer. Method Eng., 1992, vol. 35, pp. 787-806.CrossRefGoogle Scholar
  2. 2.
    I. Ohnaka and J.D. Zhu: Proc. 1995 7th Conf. Model. Casting Welding Adv. Solid Process, TMS, Warrendale, PA, 1995, pp. 971–74.Google Scholar
  3. 3.
    M.R. Barkhudarov and C.W. Hirt: Proc. 1995 7th Conf. Model. Casting Welding Adv. Solid Process, TMS, Warrendale, PA, 1995, pp. 935–46.Google Scholar
  4. 4.
    S.M. Xiong and B.C. Liu: Chin. J. Mech. Eng., 1999, vol. 12, no. 1, pp. 4–10.Google Scholar
  5. 5.
    S.V. Shepel and S. Paolucci: Appl. Therm. Eng., 2002, vol. 22, pp. 229–48.CrossRefGoogle Scholar
  6. 6.
    C.M. Chimani, R. Kretz, S. Schneiderbauer, S. Puttinger, and S. Pirker: TMS Light Metals, 2012, pp. 443–47Google Scholar
  7. 7.
    P. Cleary, J. Ha, V. Alguine, and T. Nguyen: Appl. Math. Model., 2002, vol. 26, pp. 171-90.CrossRefGoogle Scholar
  8. 8.
    X. Xue and Y.B. Zhang: Mater. Sci. Technol., 2002, vol. 10, pp. 77–80.Google Scholar
  9. 9.
    G.B. Van Der Graaf, H.E.A. Van Den Akker, and L. Katgerman: Metall. Mater. Trans. B, 2001, vol. 32B, pp. 69-78.CrossRefGoogle Scholar
  10. 10.
    F. Hou, S. Chen, X. Li, and Q. Xu: J. Tianjin University, 1993, no. 4, pp. 107–14.Google Scholar
  11. 11.
    L.N. Cai, X.J. Ma, B.J. Yang, and J.Y. Su: J. Xi’An Jiaotong University, 1999, vol. 33, no. 5, pp. 84–7.Google Scholar
  12. 12.
    Z.X. Zhao, S.T. Wang, S.L. Wen, and Y.C. Zhai: Chin. J. Nonferr. Met., 2005, vol. 15, no. 8, pp. 1263–66.Google Scholar
  13. 13.
    Z.X. Zhao, S.L. Wen, S.T. Wang, and Y.C. Zhai: Foundry, 2005, vol. 54, no. 10, pp. 1010–13.Google Scholar
  14. 14.
    M. Khodai and N. Parvin: J. Mater. Process. Technol., 2008, vol. 206(1–3), pp. 1–6.Google Scholar
  15. 15.
    S. Kashiwai, I. Ohnaka, A.K. Imatsuka, T. Kaneyoshi, T. Ohmichiand, and J. Zhu: Int. J. Cast. Metal. Res., 2005, vol. 18, no. 3, pp. 144–48.CrossRefGoogle Scholar
  16. 16.
    H.D. Zhao, I. Ohnaka, and J.D. Zhu: Appl. Math. Model., 2008, vol. 32, pp. 185-94.CrossRefGoogle Scholar
  17. 17.
    D.Z. Li, J. Campbell, and Y.Y. Li: J. Mater. Process. Technol. 2004, vol. 148, no. 3, pp. 310-16.CrossRefGoogle Scholar
  18. 18.
    S.I. Jong and W.S. Hwang: AFS Trans., 1992, vol. 100, pp. 489-97.Google Scholar
  19. 19.
    F.J. Li, H.F. Shen, B.C. Liu, and D.D. Zhang: Mater. Sci. Technol., 2003, vol. 11, no. 3, pp. 222-29.Google Scholar
  20. 20.
    J. Szekely: Fluid Flow Phenomena in Metals Processing, Academic Press, New York, NY, 1979, p. 38.Google Scholar
  21. 21.
    W.Q. Wang and K.S. Li: Foundry Technology, Machinery Industry Press, Beijing, 1998, p. 264.Google Scholar
  22. 22.
    R. Lin, Z.G. Yan, T. Liu, J.Z. Liu, and J.K. Yu: J. Mater. Metall., 2011, vol. 10, pp. 172-75.Google Scholar

Copyright information

© The Minerals, Metals & Materials Society and ASM International 2014

Authors and Affiliations

  • Jinwu Kang
    • 1
    Email author
  • Haimin Long
    • 1
  • Yongjie Li
    • 2
  • Rui You
    • 1
  • Xiaokun Hao
    • 1
  • Gang Nie
    • 1
  • Tianjiao Wang
    • 1
  • Chengchun Zhang
    • 3
  1. 1.School of Materials Science and Engineering, Key Laboratory for Advanced Materials Processing TechnologyTsinghua UniversityBeijingP.R. China
  2. 2.Department of Mechanical EngineeringTsinghua UniversityBeijingP.R. China
  3. 3.Harbin Electric Machinery Co., LTDHarbinP.R. China

Personalised recommendations