Casting defects may be defined Those characteristics that create a

deficiency or imperfection to quality specifications imposed by design

and service requirements.

Reduces total output, increases the cost of production.

Even in modern foundries the rejection rate as high up to 20% of the number
of casting produced.

Surface defects

Incorrect chemical compo.

Internal defects

Unsatisfactory mech.
properties

Surface defects : May be visible on surface, including incorrect shape & size, flashes, poor surface
finish.

Internal defects : These are present in interior of cast. Can be revealed through NDT techniques.

Incorrect chemical composition Formation of undesirable microstructure.

Unsatisfactory mechanical properties These are due to low quality, poor percent of usage.

SWELL
FIN
Gas HOLES
SHRINKAGE CAVITY
HOT TEAR
MISRUN AND COLD SHUT

Swell - enlargement of the mould cavity by metal pressures, results

localized or overall enlargement of castings
Causes

Insufficient ramming of the sand.

Rapid pouring of molten metal.

Also due to insufficient weighting of mould.

Remedies

Avoid rapid pouring.

provide sufficient ram on sands.

proper weighting of moulds.

A thin projection of metal not a part of cast.

Usually occur at the parting of mould or core sections.
Causes
Incorrect assembly of cores and moulds,
Improper clamping.
Improper sealing.
Remedy

Reduces by proper clamping of cores and mould.

.
Gas Holes
Clean, smooth walled rounded holes of varying size from pin heads to full
section thickness, often exposed during machining.
Causes
Low pouring temperature.
Gases blowing from the mould.
Excessive turbulence during pouring.
Moisture condensed on densors and chills.
Remedies
Use correct pouring temperature and check with pyrometer.

Increase permeability of sand and check grinding.

Warm densors and chills.
Modify gating to reduce turbulence, use sivex filter

Gas

HOLE

It is a void or depression in the casting caused mainly by uncontrolled solidification.

Causes:
1.
Pouring temperature is too high causing liquid shrinkage.
2.
Failure to supply liquid feed metal.
3.
Pre mature solidification.
Remedies :
Apply principles of casting, reduce the pouring temperature and provide adequate
risers, feeders, which supply the molten metal to compensate the shrinkage.

One of the main defects is hot tearing or hot cracking, or hot shortness.
Irrespective of the name, this phenomenon represents the formation of
an irreversible failure (crack) in the still semisolid casting.
Cause:
The inadequate compensation of solidification shrinkage by melt flow in
the presence of thermal stresses.
Remedy

Avoid excessive ramming.

Controlled ramming should be done.

Castings not fully form heaving lines or seam

of discontinuity or holes with rounded edges
through casting walls.

Causes:
Incomplete fusion where two streams of metal
meat.
Metal freezes before mold is filled.
Die too cold.

Remedies:
Increase pouring temperature.
Increase die temperature or improve venting.
Increase permeability of sand.

Casting Defects

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton