Casting Study: Approach Post Foot

The casting design was engineered to provide the surface finish on the decorative areas while providing adequate strength and reducing cost. The existing weldment design was problematic because of the metal fill direction through the cavity. Working with the customer, we were able to modify the flange geometry and the internal core. This provided the opportunity to vertical gate along the column and thereby reducing air entrapment and entrainment. This vertical gate along with the internal core changes, also provided improved flow direction and surface finish throughout the casting. The improved gating and overflow system was verified with flow simulations that we performed during the part and tooling design process.