A review of the casting design pointed to the
casting gating as the primary reason for shrinkage porosity
in the connecting center shaft. The
tooling design used two gates to feed molten metal into the main
cylinder on the top and into the cup on the bottom.
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The
thick center shaft was remote from the two gate inlets with no direct metal feed into the heavy section during
solidification.
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As
the thin-wall cylinder on the top and cup on the bottom solidified, metal feed into the
center shaft was restricted and porosity shrinkage formed in the
shaft.
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