Design, optimisation and manufacturing of new generation pre-formed feeder sleeves

Casting process is one of the most preferred methods in industrial production of metallic parts, in terms of ease of control, economy and applicability to mass production. Casting is an inevitable method especially for the production of large sized and single piece parts. Although the runner design is well designed for a sound casting, it is often necessary to use a feeder so that the shrinkage caused by solidification do not affect the casting. Even if feeder application decreasing the casting yield, increasing the total yield. In generally exothermic and/or insulating feeder sleeves are used in iron-based and partly non-ferrous alloys to increase casting yield. In this study, aim to design and manufacture feeder sleeves with environmental and human health friendly raw materials. For this purpose, structural and thermal properties of feeder sleeves that have four different exothermic and insulation composition, are characterized and two new geometric design are improved. Thereby, crucial parameters are revealed for application and selection of feeder sleeves. Also, casting applications were carried out by designing suitable molds in which feeder activity could be examined. Ductile iron, carbon steel, high manganese steel and stainless-steel alloys are used for casting application. The cooling curves during the castings were taken and the effects of the sleeves on the metal solidification process and the metal structure after solidification were investigated. The data obtained from feeder sleeves investigations and casting applications were processed on the casting simulation program and the characteristics of the feeder sleeves loaded in the program were improved. In this way, using the simulation program, the right feeder shirt selection is paved.