Technical Information 34

Internal Shrinkage Porosity

Shrinkage porosity in grey and ductile irons are typically present as internal cavities of
varying size and shape- from large isolated holes to more scattered and smaller porosity
only visible under the microscope. Very often a characteristic dendritic sub-structure is
revealed inside the porosities. The defect normally occurs due to contraction in the last
liquid metal to solidify and is thus often associated with heavier sections, changes in
section thickness or hot-spots in a complex casting geometry. These same locations are
also prone to release certain gas related porosity and thus it is often difficult to distinguish
between gas and shrinkage related defects.

Overview of a sample with internal shrinkage. Close-up of typical shrinkage porosity in grey
iron.

Possible causes: Possible cures:

• Soft moulds or not properly cured binder.
• Insufficient clamping or weighing.
• Excessive pouring temperature.
• Excessive inoculation giving pronounced
graphite expansion early in solidification
and thus mould wall dilatation.
• No inoculation or under-inoculation.
• Insufficient or excessive (>3.8%) carbon
content or inadequate carbon equivalent.
• Hot spots resulting from poorly designed
gates and risering systems.
• Poor casting design causing unnecessary
changes in casting section sizes.
• High percentage of steel scrap in charge
or excessive alloying or trace elements.
• Improve mould rigidity.
• Clamp or weight the moulds adequately.
• Avoid unnecessarily high pouring temperatures.
• Avoid over-inoculation.
• Adjust carbon content or carbon equivalent.
• Provide adequate feed metal by proper gating
and risering. Use solidification simulation if
necessary.
• Minimise hotspots by improving casting and
gating design. Avoid sharp radii.
• Use internal or external chills to avoid hot-spots.
• Use inoculant designed to minimise shrinkage
effects.
• Reduce concentration of alloying or trace
elements.

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