Enhancing riser design and solidification time through innovative simulations to minimize raw molten substance in sand casting: insights from NDT analysis

Riser is one of the main parts in casting process to feed the molten metal into a mould cavity to steer clear of shrinkage. The proper riser design is essential for avoiding the casting flaws. To eliminate the defects, it is necessary to design the proper riser geometry on mould cavity. This research establishes a novel approach to riser design using CATIA and ANSYS software. Through this methodology, defects in the manufacturing process of Aluminum Grade 6063 can be effectively minimized. Experimental validation through the NDT method reinforces the viability of this approach, promising enhanced product quality and reduced defects in aluminum manufacturing. In this work, the novel concept of riser design is drafted by CATIA drawing software and analyzed by ANSYS software. The Aluminum Grade 6063 is used for this investigation. It is clear that the 30% of volume is reduced from the initial raw material consumption after the solidification time will occur. The output results of the riser geometry are made by experimentally investigated and tested by Non-Destructive Test (NDT) method.