Casting Defects, Causes, and Prevention

Prepared by

Presented to

ABSTRACT

Foundryindustriesindevelopingcountriessufferfrompoorqualityand
productivityduetoinvolvementofnumberofprocessparameter.Evenin
completelycontrolledprocess,defectincastingareobservedandhencecasting
processisalsoknownasprocessofuncertaintywhichchallengesexplanation
aboutthecauseofcastingdefects.Inordertoidentifythecastingdefectand
problemrelatedtocasting,thestudyisaimedintheresearchwork.Thiswillbe
beneficialinenhancingtheyieldofcasting.Besidethis,standardization
(optimization)ofprocessparameterforentirecycleofmanufacturingofthe
criticalpartisintendedintheproposedwork.Thisstudyaimstofindingdifferent
defectsincasting,analysisofdefectandprovidingtheirremedieswiththeir
causes.Inthispaperanattempthasbeenmadetolistdifferenttypesofcasting
defectsandtheirrootcausesofoccurrence.Thispaperalsoaimstoprovide
correctguidelinetoqualitycontroldepartmenttofindcastingdefectsandwill
helpthemtoanalyzedefectswhicharenotdesired.

ii

TABLE OF CONTENT
Contents
ABSTRACT.................................................................................................................ii
LISTOFFIGURESANDTABLES..................................................................................v
ListofFigures........................................................................................................v
ListofTables...........................................................Error!Bookmarknotdefined.
1 INTRODUCTION[2]..............................................................................................1
2 TERMINOLOGY[1]...............................................................................................2
3 CASTINGDEFECTSCLASSIFICATION...................................................................2
4 Defects[3,4,5]......................................................................................................2
4.1 Fillingrelated...............................................................................................2
4.1.1 Blowholes..............................................................................................2
4.1.2 Sandburning.........................................................................................4
4.1.3 Sandinclusion........................................................................................6
4.1.4 Coldlap(shut).......................................................................................9
4.1.5 Misrun.................................................................................................10
4.1.6 Gasporosity........................................................................................11
4.2 Shapedefects............................................................................................13
4.2.1 Mismatch.............................................................................................13
4.2.2 Distortion............................................................................................13
4.2.3 FlashDefect.........................................................................................14
4.3 Thermaldefects.........................................................................................16
4.3.1 CracksandTears..................................................................................16
4.3.2 Shrinkage.............................................................................................17
4.3.3 Sinkmark.............................................................................................19
4.4 AppearanceDefects..................................................................................21
iii

4.4.1 MetallicProjection..............................................................................21
4.4.2 Cavities................................................................................................22
4.4.3 Discontinuities.....................................................................................22
4.4.4 Incompletecasting..............................................................................23
4.4.5 Incorrectdimensionorshape.............................................................24
4.4.6 Defectivesurface.................................................................................25
4.4.7 RatTailandBuckles.............................................................................26
5 CONCLUSION...................................................................................................27
REFERNCES..........................................................................................................28

iv

LIST OF FIGURES AND TABLES

List of Figures
Figure1Blowhole[2]...............................................................................................3
Figure2Sandburning[2].........................................................................................5
Figure3Sandinclusion[2].......................................................................................7
Figure4Coldshut[2]...............................................................................................9
Figure5Misrun[2].................................................................................................10
Figure6Gasporosity[2]........................................................................................11
Figure7Mismatch[2]............................................................................................13
Figure8Distortion[2]............................................................................................14
Figure9Flash[2]....................................................................................................15
Figure10Crack[2].................................................................................................16
Figure11Shrinkage[2]..........................................................................................18
Figure12Sinkmark[2]..........................................................................................19
Figure13Metallicprojection[2]............................................................................21
Figure14Blowholes[2].........................................................................................22
Figure15Bodycrack[2].........................................................................................23
Figure16Incomplete[2]........................................................................................24
Figure17Defectivesurface[2]..............................................................................25
Figure18Rattail[2]...............................................................................................26

1 INTRODUCTION [2]

Castingisaprocesswhichcarriesriskoffailureoccurrenceduringalltheprocess
ofaccomplishmentofthefinishedproduct.Hencenecessaryactionshouldbe
takenwhilemanufacturingofcastproductsothatdefectfreepartsareobtained.
Mostlycastingdefectsareconcernedwithprocessparameters.Henceonehasto
controltheprocessparametertoachievezerodefectparts.Forcontrolling
processparameteronemusthaveknowledgeabouteffectofprocessparameter
oncastingandtheirinfluenceondefect.
Toobtainthisallknowledgeaboutcastingdefect,theircauses,anddefect
remediesonehastobeanalyzecastingdefects.Castingdefectanalysisisthe
processoffindingrootcausesofoccurrenceofdefectsintherejectionofcasting
andtakingnecessarysteptoreducethedefectsandtoimprovethecastingyield.
Inthisreviewpaperanattempthasbeenmadetoprovideallcastingrelated
defectwiththeircausesandremedies.
Duringtheprocessofcasting,thereisalwaysachancewheredefectwilloccur.
Minordefectcanbeadjustedeasilybuthighrejectedratescouldleadto
significantchangeathighcost.Thereforeitisessentialfordiecastertohave
knowledgeonthetypeofdefectandbeabletoidentifytheexactrootcause,and
theirremedies.

2 TERMINOLOGY [1]

Theterms"defect"and"discontinuity"refertotwospecificandseparatethingsin
castings.Defectsaredefinedasconditionsinacastingthatmustbecorrectedor
removed,orthecastingmustberejected.Discontinuities,alsoknownas
"imperfections",aredefinedas"interruptionsinthephysicalcontinuityofthe
casting".Therefore,ifthecastingislessthanperfect,butstillusefulandin
tolerance,theimperfectionsshouldbedeemed"discontinuities".

3 CASTING DEFECTS CLASSIFICATION

1.
2.
3.
4.

Filingrelateddefects.
Shaperelateddefects.
Thermaldefects.
Defectsbyappearance.

4 Defects [3, 4, 5]
4.1 Filling related

4.1.1 Blowholes
Blowholeisakindofcavitiesdefect,whichisalsodividedintopinholeand
subsurfaceblowhole.Pinholeisverytinyhole.Subsurfaceblowholeonlycanbe
seenaftermachining.Gasesentrappedbysolidifyingmetalonthesurfaceofthe
casting,whichresultsinaroundedorovalblowholeasacavity.Frequently
associatedwithslagsoroxides.Thedefectsarenearlyalwayslocatedinthecope
partofthemouldinpoorlyventedpocketsandundercuts.
2

Figure1Blowhole[2]

4.1.1.1Causes
Resinbondedsand

Inadequatecoreventing.

Excessivereleaseofgasfromcore.

Excessivemoistureabsorptionbythecores.

Lowgaspermeabilityofthecoresand.

Claybondedsand

Moisturecontentofsandtoohigh,orwaterreleasedtooquickly.

Gaspermeabilityofthesandtoolow.

Sandtemperaturetoohigh.

Bentonitecontenttoohigh.

Toomuchgasreleasedfromlustrouscarbonproducer.

4.1.1.2Remedies
Resinbondedsand
Improvecoreventing,provideventingchannels,andensurecoreprintsarefree
ofdressing
Reduceamountsofgas.Useslowreactingbinder.
Reducequantityofbinder.Useacoarsersandifnecessary.
Applydressingtocores,thusslowingdowntherateofheatingandreducinggas
pressure.
Dryoutcoresandstoredry,thusreducingabsorptionofwaterandreducinggas
pressure.
Claybondedsand
Reducemoisturecontentofsand.Improveconditioningofthesand.
Reduceinertdustcontent.
Improvegaspermeability.Endeavourtousecoarsersand.Reduce
bentoniteandcarboncarriercontent.
Reducesandtemperature.Installasandcoolerifnecessary.Increasesand
quantity.
Reducebentonitecontent.Usebentonitewithahighmontmorillonitecontent,
highspecificbindingcapacityandgoodthermalstability.
Useslowreactinglustrouscarbonproducersorcarboncarrierswithhigher
capacityforproducinglustrouscarbon.Inthelastinstance,thecontentofcarbon
carriersinthemouldingsandcanbereduced.

4.1.2 Sand burning

Burningondefectisalsocalledassandburning,whichincludeschemicalburnon,
andmetalpenetration.
4

Figure2Sandburning[2]

4.1.2.1 Causes
Claybondedsand
Lustrouscarboncontenttoolow.
Proportionoflowmeltingpointsubstancestoohigh.
Mouldingplant
Unevenmouldcompaction
Gatingandpouringpractice
Unevendistributionofinflowingmetalwithresultantoverheating.
Temperatureofliquidmetaltoohigh.

4.1.2.2 Remedies
Claybondedsand

Increaseproportionoflustrouscarbonproducer.Thisincreasesthe
amountofcokeaswellastheamountoflustrouscarbon,whichthenresultsin
positiveseparationbetweenmouldandmetal.
5

Usepurersilicasandsor,ifnecessary,addnewsand.Reducedustcontent.If
necessary,reducetheamountofbentonite.
Mouldingplant
Ensureuniformcompaction.Ifnecessary,increaseheatremovalfromthe
moulds.
Gatingandpouringpractice
Evenoutincomingmetalflow.
Reducepouringrate.
4.1.3 Sand inclusion

Sandinclusionandslaginclusionarealsocalledasscaborblackingscab.Theyare
inclusiondefects.Lookslikethereareslaginsideofmetalcastings.
Irregularlyformedsandinclusions,closetothecastingsurface,combinedwith
metallicprotuberancesatotherpoints.Sandinclusionisoneofthemostfrequent
causesofcastingrejection.Itisoftendifficulttodiagnose,asthesedefects
generallyoccuratwidelyvaryingpositionsandarethereforeverydifficultto
attributetoalocalcause.Areasofsandareoftentornawaybythemetalstream
andthenfloattothesurfaceofthecastingbecausetheycannotbewettedbythe
moltenmetal.SandinclusionsfrequentlyappearinassociationwithCOblowholes
andslagparticles.Sandinclusionscanalsobetrappedunderthecastingsurfacein
combinationwithmetaloxidesandslags,andonlybecomevisibleduring
machining.Ifaloosesectionofsandiswashedawayfromonepartofthemould,
metallicprotuberanceswilloccurhereandhavetoberemoved.


Figure3Sandinclusion[2]

4.1.3.1 Causes
Mouldingplant
Breakupofmouldsectionsduringstrippingofpatterns,coresettingor
assemblingofmouldingflasks
Unevencompactionofmoulds,compactiontoohighinplaces.

Claybondedsand
Lowcompatibility.
Bentonitecontenttoolow,orpoorlydevelopedbentonite.
Inertmaterialcontenttoohigh.
Lumpcontenttoohigh.
Highcontentoflustrouscarbonproducer.
Resinbondedsand
Lowcorestrength.
Excessivecoremismatching.
7

Gatingandpouringpractice
Pouringratetoohigh,withheavyimpactagainstmouldwallsurfaceresultingin
erosion.
Ladletoofarabovepouringbasin.
Pouringtimetoolong.

4.1.3.2 Remedies
Mouldingplant
Checkmouldsforpressuremarksand,ifnecessary,insertpressurepads
Carefullyblowoutmouldcavities.
Improvepatternplates,increasepatterntapersandradii.Heatpatternplates
and,ifnecessary,usereleaseagent.
Checkthemouldingplantforuniformflaskstrippingandoverhaulmoulding
plantasnecessary.
Automatecoresetting.Checkand,ifnecessary,modifycoreprintsbeforestart
ofproduction.
Ensureuniformmouldcompaction,avoidovercompactedsections.
Claybondedsand
Raisecompactibilityandthusplasticityofthesand.
Increasebentonitecontent.Usebentonitewithhighspecificbindingcapacity.
Improvebentonitedevelopmentbyextendingmixingtimeorbyprewetting
usedsand.
Reduceinertdustcontent.Decreasingthedustcontentreduceslumpsinthe
sand.
Reducecontentoflustrouscarbonproducer.
8

Resinbondedsand
Increasethestrengthofthecores.Usegreaterproportionofbinder.
Compactcoresmoreevenlyandeffectivelyand,ifnecessary,injectgasmore
evenly.
Avoidcoremismatching.
Gatingandpouringpractice
Avoidhighpouringratesandimpactofmetalstreamagainstmouldwalls.
Shortenpouringtimes,improvedistributionofgates.

4.1.4 Cold lap (shut)

Coldlaporalsocalledascoldshut.Itisacrackwithroundedges.Coldlapis
becauseoflowmeltingtemperatureorpoorgatingsystem.
Whenthemetalisunabletofillthemouldcavitycompletelyandthusleaving
unfilledportioncalledmisrun.Acoldshuntiscalledwhentwometalstreamsdo
notfusetogetherproperly.

Figure4Coldshut[2]

4.1.4.1 Causes
Lackoffluidityinmoltenmetal.
Faultydesign.
Faultygating.

4.1.4.2 Remedies
Adjustproperpouringtemperature.
Modifydesign.
Modifygatingsystem.

4.1.5 Misrun

Misrundefectisakindofincompletecastingdefect,whichcausesthecasting
uncompleted.Theedgeofdefectisroundandsmooth.
Whenthemetalisunabletofillthemouldcavitycompletelyandthusleaving
unfilledportioncalledmisrun.Acoldshuntiscalledwhentwometalstreamsdo
notfusetogetherproperly.

Figure5Misrun[2]

10

4.1.5.1 Causes
Lackoffluidityinmoltenmetal.
Faultydesign.
Faultygating.

4.1.5.2 Remedies
Adjustproperpouringtemperature.
Modifydesign.
Modifygatingsystem.

4.1.6 Gas porosity

Thegascanbefromtrappedair,hydrogendissolvedinaluminumalloys,moisture
fromwaterbaseddielubricantsorsteamfromcrackedcoolinglines.
Airispresentinthecavitybeforetheshot.Itcaneasilybetrappedasthemetal
startstofillthecavity.Theairisthencompressedasmoreandmoremetal
streamsintothecavityandthepressurerises.Whenthecavityisfullitbecomes
dispersedassmallspheresofhighpressureair.Theswirlingflowcancausethem
tobecomeelongated.

Figure6Gasporosity[2]

11

4.1.6.1 Causes
Metalpouringtemperaturetoolow.
Insufficientmetalfluiditye.g.carbonequivalenttoolow.
Pouringtooslow.
Slagonthemetalsurface.
Interruptiontopouringduringfillingofthemould.
Highgaspressureinthemouldarisingfrommoldingmaterialhavinghigh
moistureand/orvolatilecontentand/orlowpermeability.
Lustrouscarbonfromthemoldingprocess.
Metalsectiontoothin.
Inadequatelypreheatedmetallicmoulds.

4.1.6.2 Remedies
Increasemetalpouringtemperature.
Modifymetalcompositiontoimprovefluidity.
Pourmetalasrapidlyaspossiblewithoutinterruption.Improvemouldfillingby
modificationtorunningandgatingsystem.
Removeslagfrommetalsurface.
Reducegaspressureinthemouldbyappropriateadjustmenttomoulding
materialpropertiesandensuring
Adequateventingofmouldsandcores.
Eliminatelustrouscarbonwhereapplicable.
Ifpossible,modifycastingdesigntoavoidthinsections.
Ensuremetalmouldsareadequatelypreheatedanduseinsulatingcoatings.
12

4.2 Shape defects

4.2.1 Mismatch

Mismatchinmolddefectisbecauseoftheshiftingmoldingflashes.Itwillcause
thedislocationatthepartingline.

Figure7Mismatch[2]

4.2.1.1 Causes
Amismatchiscausedbythecopeanddragpartsofthemouldnotremainingin
theirproperposition.
Thisiscausedbylooseboxpins,inaccuratepatterndowelpinsorcarelessnessin
placingthecopeonthedrag.

4.2.1.2 Remedies
CheckpatternmountingonmatchplateandRectify,correctdowels.
Usepropermoldingboxandclosingpins.
4.2.2 Distortion

WarpedCastingDistortionduetowarpageisknownaswarpdefect.
13


Figure8Distortion[2]

4.2.2.1 Causes
Distortionduetowarpagecanoccurovertimeinacastingthatpartiallyor
completelyliberatesresidualstresses.

4.2.2.2 Remedies
Commonpracticeinironcastingisnormalizingheattreatmenttoremoveresidual
stress.Inaluminumcasting,astraighteningbetweenquenchandagingmightbe
required.

4.2.3 Flash Defect

Flashcanbedescribedasanyunwanted,excessmetalwhichcomesoutofthedie
attachedtothecavityorrunner.
Typicallyitformsathinsheetofmetalatthepartingfaces.
Thereareanumberofdifferentcausesofflashandtheamountandseveritycan
varyfromaminorinconveniencetoamajorqualityissue.
Attheveryleast,flashiswastematerial,whichmainlyturnsintodrosswhenre
melted,andthereforeisahiddencosttothebusiness.
14


Figure9Flash[2]

4.2.3.1 Causes
Damagetodiefacesanddiecomponents.
Partsofthediehaveinsufficientstrength.
Bending,crowningofstretchingofdies.
Cavitiesoffsetfromcentreofplaten.
Insufficientmachineclampup.
Pressurespikesattheendofcavityfill.
Excessiveintensificationpressure.
Incorrectintensificationtiming.
Damage,orwear,intogglemechanisms.
Machinehydraulicmalfunction.
Hydraulicvalveorsealleaks.

15

4.2.3.2 Remedies
Ifyoursprueisverytallandthecastingcoversawideareaofthemoldface,it's
verypossibleforthemoldtoactuallybeforcedupbythehydrostaticpressureof
themetal.Theseriousnessofthisdependsdensityofthemetal(aluminumisvery
light,butbecarefulwithabronzepour!)andtheweightofthemoldfightingit.
Thesolutionhereisverysimple:weightdownthemould.

4.3 Thermal defects

4.3.1 Cracks and Tears

Crackscanappearindiecastingsfromanumberofcauses.Somecracksarevery
obviousandcaneasilybeseenwiththenakedeye.Othercracksareverydifficult
toseewithoutmagnification.

Figure10Crack[2]

4.3.1.1 Causes
Shrinkageofthecastingwithinthedie.
Undercutsordamageindiecavities.
Uneven,orexcessive,ejectionforces.
Thermalimbalanceinthedie
16

Insufficientdraftinsectionsofthedie.
Excessiveporosityincriticalregionsofthepart.
Productdesignnotmatchedtotheprocess.
Inadequatediedesign.

4.3.1.2 Remedies
Reducedrystrength,addsawdust/coaldust.
Reducepouringtemperature.
Avoidsuperheatingofmetal.
Usechills.
Providefeeders.
Avoidearlyknockoutandgivesufficientcoolingtime.
Correctcomposition.
Reducesharpcorners.

4.3.2 Shrinkage
Shrinkagedefectsoccurwhenfeedmetalisnotavailabletocompensatefor
shrinkageasthemetalsolidifies.Shrinkagedefectscanbesplitintotwodifferent
types:openshrinkagedefectsandclosedshrinkagedefects.Openshrinkage
defectsareopentotheatmosphere,thereforeastheshrinkagecavityformsair
compensates.Therearetwotypesofopenairdefects:pipesandcavedsurfaces.
Pipesformatthesurfaceofthecastingandburrowintothecasting,whilecaved
surfacesareshallowcavitiesthatformacrossthesurfaceofthecasting.
Closedshrinkagedefects,alsoknownasshrinkageporosity,aredefectsthatform
withinthecasting.Isolatedpoolsofliquidforminsidesolidifiedmetal,whichare
17

calledhotspots.Theshrinkagedefectusuallyformsatthetopofthehotspots.
Theyrequireanucleationpoint,soimpuritiesanddissolvedgascaninduceclosed
shrinkagedefects.Thedefectsarebrokenupintomacroporosityandmicro
porosity(ormicroshrinkage),wheremacroporositycanbeseenby.

Figure11Shrinkage[2]

4.3.2.1 Causes
Thedensityofadiecastingalloyinthemoltenstateislessthanitsdensityinthe
solidstate.Therefore,whenanalloychangesphasefromthemoltenstatetothe
solidstate,italwaysshrinksinsize.
Thisshrinkagetakesplacewhenthecastingissolidifyinginsideadiecastingdie.
Atthecenterofthicksectionsofacasting,thisshrinkagecanendupasmany
smallvoidsknownasshrinkageporosity.
Iftheshrinkageporosityissmallindiameterandconfinedtotheverycenterof
thicksectionsitwillusuallycausenoproblems.
However,ifitislargerinsize,orjoinedtogether,itcanseverelyweakenacasting.
Itisalsoaparticularproblemforcastingswhichneedtobegastightorwater
tight.

18

4.3.2.2 Remedies
Thegeneraltechniqueforeliminatingshrinkageporosityistoensurethatliquid
metalunderpressurecontinuestoflowintothevoidsastheyform.

4.3.3 Sink mark

SolvingmoldingsinkmarkandvoidproblemsDefinition:Sinkmarksandvoids
bothresultfromlocalizedshrinkageofthematerialatthicksectionswithout
sufficientcompensation.
Sinkmarksappearasdepressionsonthesurfaceofamoldedpart.These
depressionsaretypicallyverysmall;howevertheyareoftenquitevisible,because
theyreflectlightindifferentdirectionstothepart.Thevisibilityofsinkmarksisa
functionofthecolorofthepartaswellasitssurfacetexturesodepthisonlyone
criterion.Althoughsinkmarksdonotaffectpartstrengthorfunction,theyare
perceivedtobeseverequalitydefects.
Voidsareholesenclosedinsideapart.Thesecanbeasingleholeoragroupof
smallerholes.Voidsarecausedwhentheouterskinofthepartisstiffenoughto
resisttheshrinkageforcesthuspreventingasurfacedepression.Instead,the
materialcorewillshrink,creatingvoidsinsidethepart.Voidsmayhavesevere
impactonthestructuralperformanceofthepart.Moldingsinkmarkandvoid.

Figure12Sinkmark[2]

19


4.3.3.1 Causes
Sinkmarksarecausedmainlybythermalcontraction(shrinkage)duringcooling.
Afterthematerialontheoutsidehascooledandsolidified,thecorematerial
startstocool.Itsshrinkagepullsthesurfaceofthemainwallinward,causinga
sinkmark.Iftheskinisrigidenough,deformationoftheskinmaybereplacedby
formationofavoidinthecore.
Localizedgeometricfeaturessinkmarkstypicallyoccurinmoldingswiththicker
sections,oratlocationsoppositefromribs,bossesorinternalfillets.
Highvolumetricshrinkage.
Insufficientmaterialcompensation.
Earlygatefreezeofforlowpackingpressuremaynotpackthecavityproperly.
Shortpackingorcoolingtime.
Highmeltand/ormoldtemperatures.

4.3.3.2 Remedies
Assinkmarksoccurduringpacking,themost.
Effectivewaytoreduceoreliminatethemistocontrolthepackingpressure
correctly.Todeterminetheeffectsofpackingonsinkmarks,usea
simulationpackagesuchasMoldflowPlasticsInsight.
Changepartgeometry.
Alterpartdesigntoavoidthicksectionsandreduce.
Thethicknessofanyfeaturesthatintersectwiththemainsurface.
Reducevolumetricshrinkage.
Relocategatestoproblemareas.
Optimizetherunnersystemdesign
Restrictiverunnersystemdesigncanresultin
prematuregatefreezeoff.
20

4.4 Appearance Defects

4.4.1 Metallic Projection

Jointflashorfins.Flatprojectionofirregularthickness,oftenwithlacyedges,
perpendiculartooneofthefacesofthecasting.Itoccursalongthejointor
partinglineofthemold,atacoreprint,orwherevertwoelementsofthemold
intersect.

Figure13Metallicprojection[2]

4.4.1.1 Causes
Clearancebetweentwoelementsofthemoldorbetweenmoldandcore;poorly
fitmoldjoint.

4.4.1.2 Remedies
Careinpatternmaking,moldingandcoremaking.Controloftheirdimensions;
Careincoresettingandmoldassembly.

21

4.4.2 Cavities

Blowholes,pinholes,Smoothwalledcavities,essentiallyspherical,oftennot
contactingtheexternalcastingsurface(Blowholes).Thedefectcanappearinall
regionsofthecasting.

Figure14Blowholes[2]

4.4.2.1 Causes
Blowholesandpinholesareproducedbecauseofgasentrappedinthemetal
duringthecourseofsolidification.

4.4.2.2 Remedies
Makeadequateprovisionforevacuationofairandgasfromthemoldcavity;
Increasepermeabilityofmoldandcores.

4.4.3 Discontinuities
Hotcracking.Acrackoftenscarcelyvisiblebecausethecastingingeneralhasnot
separatedintofragments.Thefracturesurfacesmaybediscoloredbecauseof
oxidation.Thedesignofthecastingissuchthatthecrackwouldnotbeexpected
toresultfromconstraintsduringcooling.
22


Figure15Bodycrack[2]

4.4.3.1 Causes
Damagetothecastingwhilehotduetoroughhandlingorexcessivetemperature
atshakeout.

4.4.3.2 Remedies
Careinshakeoutandinhandlingthecastingwhileitisstillhot;Sufficientcooling
ofthecastinginthemold.

4.4.4 Incomplete casting

Pouredshort.Theupperportionofthecastingismissing.Theedgesadjacentto
themissingsectionareslightlyrounded;allothercontoursconformtothe
pattern.Thespree,risersandlateralventsarefilledonlytothesameheight
abovethepartingline,asisthecasting.

23


Figure16Incomplete[2]

4.4.4.1 Causes
Insufficientquantityofliquidmetalintheladle.Prematureinterruptionof
pouringduetoworkmanserror.

4.4.4.2 Remedies
Havesufficientmetalintheladletofillthemold,Checkthegatingsystem.
Instructpouringcrewandsupervisepouringpractice.

4.4.5 Incorrect dimension or shape

Distortedcasting.Inadequatethickness,extendingoverlargeareasofthecopeor
dragsurfacesatthetimethemoldisrammed.

4.4.5.1 Causes
Rigidityofthepatternorpatternplateisnotsufficienttowithstandthe
rammingpressureappliedtothesand.Theresultisanelasticdeformationofthe
patternandacorresponding,permanentdeformationofthemoldcavity.In
diagnosingthecondition,thecomparethesurfacesofthepatternwiththoseof
themolditself.
24


4.4.5.2 Remedies
Assureadequaterigidityofpatternsandpatternplates,especiallywhensqueeze
pressuresarebeingincreased.

4.4.6 Defective surface

Flowmarks.Onthesurfacesofotherwisesoundcastings,thedefectappearsas
lineswhichtracetheflowofthestreamsofliquidmetal.

Figure17Defectivesurface[2]

4.4.6.1 Causes
Oxidefilmswhichlodgeatthesurface,partiallymarkingthepathsofmetalflow
throughthemold.
4.4.6.2Remedies
Increasemoldtemperature;
Lowerthepouringtemperature;
Modifygatesizeandlocation.
Tiltthemoldduringpouring.
25


4.4.7 Rat Tail and Buckles

Rattailsandbucklesarecausedbytheexpansionofathinouterlayerof
mouldingsandonthesurfaceofthemouldcavityduetometalheat.

Figure18Rattail[2]

4.4.7.1 Causes

Arattailiscausedbydepressionofapartofthemouldundercompression
whichappearsasanirregularlineonthesurfaceofthecasting.

Abuckleisamoreseverefailureofthesandsurfaceundercompression.

4.4.7.2 Remedies
Themouldmustprovideforproperexpansioninsteadofformingcompressed
layerstoavoidthisdefect.

26

5 CONCLUSION

Inthisresearchworkdifferentcastingdefectsarestudied.Byreferringdifferent
researchpaperscausesandtheirremediesarelisted.Thesewillhelptoquality
controldepartmentofcastingindustriesforanalysisofcastingdefect.Thisstudy
willdefinitelybehelpfulinimprovingtheproductivityandyieldofthecasting.
Rejectionsofthecastingonthebasisofthecastingdefectshouldbeasminimized
andalltheaboveresearchisheadinginthesamedirection.

27

REFERNCES

[1]
[2]

[3]
[4]
[5]

Wikipedia
http://en.wikipedia.org/
Google
https://www.google.com.eg/search?q=casting+defects+distortion&espv=2
&biw=1366&bih=624&source=lnms&tbm=isch&sa=X&ei=hZZmVJ2cGcLJOf
9gdAO&ved=0CAYQ_AUoAQ#tbm=isch&q=defected+casting&imgdii=_
Slideshare
http://www.slideshare.net/pallawisinha9/castingdefects

http://www.ijrat.org/downloads/march2014/paper%20id232014109.pdf

28