Casting Simulation on the Integrated Twin-Scroll Turbine Housing with Exhaust Manifold

In this paper, the casting design of the integrated twin-scroll turbine housing with exhaust manifold using stainless steel is investigated. Due to the complexity in its geometry and the poor castability of stainless steel, it is more crucial to set up the appropriate casting design to avoid casting defects. Gas porosity and shrinkage formation with the changes of gating systems (one-/two-side), riser conditions and pouring temperatures are examined via casting simulation and virtual castings. Simulation results show that two-side gating system produced better quality casting than that of one-side gating system, minimizing the gas content of the castings and it is also verified by X-ray analysis for the virtual castings. For the changes of riser conditions and pouring temperatures in the two-side gating system, it is found that the change of the height of two risers plays an important role in obtaining the best quality by reducing shrinkage defects.