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Casting Defects
A defect may be the result of single clearly defined cause or of a combination of factors, in
which case necessary preventive measures are more obscure.
Defects or flows affect appearance or the satisfactory functioning of the casting and
the casting do not come up to the quality standard applied.
Any irregularity in molding process causes defects in cast components which may be
sometimes tolerated, eliminated with proper molding practice or repaired using
methods such as welding and metallization.
Classification of Defects
Defects found in casting are divided into three classes:
1.
2.
Defects which exist under the surface and are revealed by machining, sectioning and
radiography.
3.
Classification of Defects
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Warpage
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2.
3.
4.
Crush
There is mismatching of the top and bottom parts of the casting at partying line.
Causes:
Remedies:
Remedies:
They usually occur at the parting line and result in excess metal which needs to be ground off.
It is the displacement of the sand while closing a mold, thereby deforming the mold surfaces.
Causes:
Pattern plates are not sufficiently rigid to keep straight during ramming
Mold halves not properly fitting together due to improper fastening of the cope to the drag.
Movement of the mold makes a casting appreciably thicker than the pattern.
Patterns having insufficient taper and thus requiring excessive rapping for their withdrawal results in fins at the joint.
Remedies:
Crush
It is displacement of the sand while closing a mold, thereby deforming mold surfaces.
Causes:
Remedies:
1.
Blowholes
2.
Drop
3.
Scab
4.
Pin-holes
5.
6.
Hot Tears
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Blowholes
Blowholes visible on the surface of a casting are called as open holes whereas blowholes occurring below the surface of the casting and not visible from outside
are termed as blowholes.
Blowholes may occur in clusters or they may be one large smooth depression.
Causes:
Remedies:
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Drop
A drop occurs when cope surface cracks and breaks, thus the pieces of the sand fall into
the molten metal.
Causes:
Remedies:
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Scab
The metal penetrates behind the surface layer of sand in a thin layer.
Causes:
Intermittent or slow running of molten metal over the sand surface thereby producing intense local heating.
Remedies:
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Pinholes
Pinholes are numerous very small holes revealed on the surface of the casting.
Causes:
Remedies:
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Molten metal enters into the space between the sand grains which causing metal penetration.
This defect appears as an uneven and rough external surface of the casting.
Causes:
High permeability
Soft ramming
Remedies:
Hot Tears
Hot tears are internal or external ragged discontinuities or crack on the casting
surface.
Immediately after solidification the metal have low strength; at this stage solid shrinkage of
the casting develops sufficiently high stresses and causes hot tears.
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Hot Tears
Causes:
Proper fillets or corner radii are not provided and chills are inappropriately placed.
Improper placement of gates and risers can also create hot tears.
Remedies:
Method to prevent hot tears may involve improving the casting design, achieving directional solidification and even rate of cooling all
over, selecting proper mold and controlling the mold hardness in relation to other ingredients of sand.
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The defects due to improper sand mixing and distribution give rise to faulty sand conditions
and various defects as follows:
1.
Blowholes
2.
Drop
3.
Scab
4.
Pin-holes
5.
6.
Hot Tears
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Hot Tears
2.
Shifts
3.
4.
Crush
5.
6.
Slag holes
7.
Shrinkage Defects
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If the molten metal has low temperature or casting section is too thin, the entire mold cavity may not be filled during pouring
before molten metal starts solidifying thus result in Misrun.
If molten metal enters the mold cavity through two or more ingates and two streams do not fuse together in the mold cavity, they
develop cold shut.
Causes:
Remedies:
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Slag Holes
Causes:
Slag holes occur when the slag enters the mold cavity.
Remedy:
They can be avoided by entering the slag traps in the gating system
The runner extension helps to accumulate the slag and avoids the slag holes.
Shrinkage
Remedy:
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A layer of moisture collected under the impervious layer of mold paint causes sand and
paint to scab, peel, creates blowholes, etc.
2.
Oil sand cores, if over-backed, are not strong enough to resist the flow of molten metal
which cause sand washes, rough surface, metal penetration and undersized
holes.
3.
Oil sand cores, if under-backed, absorb moisture from atmosphere or green sand mold
and cause defects like core sand wash, blowholes, etc.
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Shifts or Mismatch
2.
Misrun
3.
4.
Crush
5.
Run Out
6.
Inclusions
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Run Out
Run out occurs when molten metal leaks out of the mold during pouring and result in
incomplete casting.
Causes:
Remedies:
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Inclusions
An inclusion may be oxide, slag, refractory materials, sand, dirt, etc. which enters
the mold cavity along with the molten metal during pouring.
Remedies:
Skimming off or screening of the molten metal before pouring into the mold cavity .
The provision of choke in the gating system and the pouring basin at the top of the mold
can prevent this defect.
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Misruns
2.
Cold Shuts
3.
Excessive Penetration
4.
5.
Hot Tears
6.
7.
Fusion
8.
9.
Shot Metal
10.
11.
Swell
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Porosity
The main gases dissolved by practically all metals are oxygen, nitrogen and hydrogen.
Molten metal may absorb hydrogen from, unburnt fuel gas, moisture in the air, dampness in the furnace and green sand mold.
Porosity occurs in material as they change state, from liquid to solid during the casting process.
Causes:
Damp ladles
Remedies:
Adequate fluxing of metal and controlling the amount of gas-producing materials in the molding and core making sand mixes can help in minimizing this defect.
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Swell
It is an enlargement of the mold cavity due to molten metal pressure on the mold wall and
the sides.
Causes:
Soft ramming
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Warpage
Castings warp, misalign or deform because of the stresses set up in them internally.
Stresses are generated due to differential solidification rates experienced by different
sections of large, long castings.
Causes:
Insufficient gating system that may not allow rapid pouring of metal or due to low green
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