Prediction of casting defects and optimization of casting process during gravity casting of A1 turbo charger valve housing

Abstract

Demand for improving fuel efficiency has been increasing and the adoption of new components such as turbo charger is widely used for better fuel consumption. Recently, the use of turbo chargers in the automobile industry has been increasing for use in gasoline engines, and two stage turbo charger systems are being developed. The shape of the valve housing used for the two stage turbo charger is very complex and prone to formation of shrinkage defects during casting process. In this study, the casting process has been simulated while varying the size of risers and the core materials in order to verify the effects of cooling rate. The core materials tested are sand and steel, and their effects on solidification and casting processes are discussed.