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Minimize the Number of Sections

A well-designed casting brings the minimum number of sections together at one point. A simple wall section will cool freely from all surfaces, but by adding a section (forming a T), a hot spot is created at the junction, and it will cool like a wall that is 50% larger.

Staggering sections minimizes hot spot effects, thus eliminating weakness and reducing distortion. If staggering is not possible, a cored hole through the center of the junction will help to speed solidification and avoid hot spots (Fig. 4).

Fig. 4a - 4b: To prevent uneven cooling, bring the minimum number of sections together or stagger them so that no more than two sections conjoin. When this is not possible, a circular web with adjoining sections is the preferred way to design structures that must intersect (4b).

A cored hole through the center of the junction will help to speed solidification and avoid hot spots - illustration

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10 Rules for Engineered Quality

This article was adopted from a section of Casting World Magazine. Reprinted with permission.