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CASTING DEFECTS
SURFACE
METALLIC PROJECTION
Swell, Crush, Mould Drop, Fillet Vein
DEFECTIVE SURFACE
Erosion Scab, Fusion, Expansion Scab,
Rat tails, Buckle, Seams, Gas Runs, Fillet
Scab, Rough Surface, Slag Inclusion,
Elephant Skin
CHANGE IN DIMENSIONWarped casting
INCOMPLETE CASTINGMisrun, Run out
CAVITYBlow Holes, Shrinkage cavity, Pinholes
DISCONTINUITYHot Cracking, Cold Shut, Cold Cracking
SUBSURFACE
SUBSURFACE CAVITYBlow Holes, Pin Holes,
Shrinkage
Porosity, Internal
Shrinkage, Severe
Roughness
INCLUSIONSGas Inclusions, Slag, Blow
Holes
DISCONTINUITYCold Shuts
Repairability
Cavities
Possible Causes
Remedies
Make adequate provision for evacuation of air
and gas from the mold cavity
Increase permeability of mold and cores
Avoid improper gating systems
Assure adequate baking of dry sand molds
Control moisture levels in green sand molding
Reduce amounts of binders and additives used
or change to other types; -use blackings and
washes, which provide a reducing atmosphere; keep the spree filled and reduce pouring height
Increase static pressure by enlarging runner
height.
Discontinuities
Possible Causes
Damage to the casting while hot due to rough handling or excessive
temperature at shakeout.
Remedies
Care in shakeout and in handling the casting while it is still hot;
Sufficient cooling of the casting in the mold;
For metallic molds; delay knockout, assure mold alignment, use
ejector pins
Defective Surface
Flow marks. On the surfaces of otherwise sound castings,
the defect appears as lines which trace the flow of the
streams of liquid metal.
Possible Causes
Oxide films which lodge at the surface, partially marking the
paths of metal flow through the mold.
Remedies
Increase mold temperature;
Lower the pouring temperature;
Modify gate size and location (for permanent molding by
gravity or low pressure);
Tilt the mold during pouring;
In die casting: vapor blast or sand blast mold surfaces which
are perpendicular, or nearly perpendicular, to the mold
parting line.
Incomplete Casting
Poured short. The upper portion of the casting is missing.
The edges adjacent to the missing section are slightly
rounded, all other contours conform to the pattern. The
spree, risers and lateral vents are filled only to the same
height above the parting line, as is the casting (contrary to
what is observed in the case of defect).
Possible Causes
Insufficient quantity of liquid metal in the ladle;
Premature interruption of pouring due to workmans error.
Remedies
Have sufficient metal in the ladle to fill the mold;
Check the gating system;
Instruct pouring crew and supervise pouring practice.
Possible Causes
Combinations formed as intermetallics between the melt and metallic impurities
(foreign impurities);
Charge materials or alloy additions which have not completely dissolved in the
melt;
Exposed core wires or rods;
During solidification, insoluble intermetallic compounds form and segregate,
concentrating in the residual liquid.
Remedies
Assure that charge materials are clean; eliminate foreign metals;
Use small pieces of alloying material and master alloys in making up the charge;
Be sure that the bath is hot enough when making the additions;
Do not make addition too near to the time of pouring;
For nonferrous alloys, protect cast iron crucibles with a suitable wash coating
POROSITY
Pattern is improperly sprued. Sprues may be
too thin, too long or not attached in the proper
location, causing shrinkage porosity.
Not enough metal reservoir to eliminate
shrinkage porosity.
Metal contains gas.
Mold is too hot.
Too much moisture in the flux.
Too much remelt being used. Always use at
least 50% new metal.
Metal is overheated.
Poor mold burnout.
ROUGH CASTINGS
A poor quality pattern
Flask was not sufficiently cured before
placing into burnout oven.
Flask was held in steam dewax too long.
Metal, flask or both were too hot.
Patterns were improperly sprued.
Flask was placed too close to heat source
in burnout oven.
BUBBLES OR NODULES ON
CASTINGS
Vacuum pump is leaking air.
Vacuum pump has water in the oil.
Vacuum pump is low on oil.
Investment not mixed properly or long
enough.
Invested flasks were not vibrated during
vacuum cycle.
Vacuum extended past working time.
SHINY CASTINGS
Carbon residue was left in the mold,
creating a reducing condition on the
surface.
NITC
DESIGN CONSIDERATIONS
CAREFUL CONTROL OF LARGE NUMBER OF
VARIABLES NEEDED
CHARACTERISTICS OF METALS & ALLOYS
CAST
METHOD OF CASTING
MOULD DESIGN
GATING SYSTEM
DESIGN CONSIDERATIONS
NITC
NITC
NITC
NITC
NITC
NITC
NITC
INSPECTION OF CASTINGS
SEVERAL METHODS
VISUAL
OPTICAL
- FOR SURFACE DEFECTS
SUBSURFACE AND
INTERNAL DEFECTS
THROUGH
PRESSURE TIGHTNESS OF
VALVES BY SEALING THE
OPENING AND
PRESSURISING WITH
WATER
EXERCISE
RECEIPT OF ORDER
(REVIEW)
ARE THE TERMS ACCEPTED? NO
COMMUNICATENEGOTIATE
YES
PREPARE WORK ORDER
WORK ORDER TO Q.C, INSPECTION, PLANNING, METHODS,
PRODUCTION AND DESPATCH
PRODUCTION PLAN
METHOD DRAWING, QA DATA, PATTERN PLAN
MOULDING
WORK ORDER, CORE MAKING, HEAT CONFORMATION
MELTING AND POURING
FOR THESE, LAB TEST REPORTS
KNOCK OUT
STAGE ISPECTION- NOT OK, REJECT
OK, SHOT BLASTING, GAS CUTTING/ARC CUTTING
ASTM STANDARDS
HEAT TREATMENT
ROUGH FETTLING, FINISH FETTLING,
INSPECTION
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entrapment during the slow shot phase on a
variety of parts, including these outboard
engine covers
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