Identifying Molding Problems

This easy-to-use reference table aids foundries in determining which variables

are causing their mold problems and/or resulting casting defects.
A modern casting Staff Report

reen sand moldmaking is

equal parts technology, process and experience. However, even with the highest levels of
technology, an efficient and perfected
mold production process, and a
moldmaker with more than 30 years of
experience, molding related-problems
and defects still occur.
The key when problems or defects
arise is to analyze the situation, isolate
the problem or defect, and eliminate it.
In pursuit of this objective, modern casting has published the following easy-touse reference tables for identifying molding-related problems and casting defects. Prepared by an AFS Molding Methods & Materials Div. Green Sand Molding Committee (4-M) for the AFS book

High-Density Molding-Related
Casting Defects

An Operating Guide to High-Density

Molding, these tables list molding problems or defects and the variables that
could be causing the problem/defect.
For example, for a mold that has
friable edges, the molding variables that
could be causing the problem are (in
order of probable contribution): hot
sand, low moisture, high methylene
blue clay, pattern problems, low methylene blue clay and/or equipment problems. For the casting defect of veining,
the molding variables that could be
causing the problem are (in order of
probable contribution): low cushion/
carbonaceous material, high moisture, uneven mold hardness, low
moisture, wrong preblend or mixture,
lack of mold vents, mold wall move-

ment, hard molds or cores, and/or

excessive metal temperature.
These tables may not solve your molding problems, but they will help isolate
problem variables for easy identification. Often, isolating the molding-related
problem is more difficult than solving it
due to all the variables interacting in
the green sand molding process.
As an added value to its readers, modern casting also has posted this easy to
use reference table on its website at
www.moderncasting.com. This table can
be printed or copied to another document to be distributed to foundry quality
control and molding personnel.
Alfred T. Spada, managing editor
For a free copy of this article circle No. 337 on the
Reader Action Card.

Causes
Causes

Shift ........................................................................................................ 12,11 and 18

Ram-Away ............................................................................................. 18,1, 4 and 3
Burn-in ............................................................ 1, 4, 24, 5, 9, 10, 19, 16, 21, 22 and 8
Blows ................................................................ 1, 3, 4, 10, 24, 19, 14, 20, 15 and 26
Scabs ............................................. 1, 15, 2, 4, 6, 7, 10, 21, 22, 13, 16, 28, 17 and 6
Sand Inclusions ........................................................ 2, 3, 4, 22, 28, 27, 24, 10 and 5

1.
2.
3.
4.
5.
6.
7.
8.
9.

High Moisture
Low Moisture
High Methylene Blue Clay
Low Methylene Blue Clay
Poor Ram or Squeeze
Mold Spray Application
Mold Spray Baum
High Ferrostatic Head
Mold Spray Not Dry

10. Excessive Pattern Spray

Cracked Casting ........................................................................... 1, 3, 11, 15 and 26

11. Equipment Problems

Crushes ....................................................................... 2, 3, 11, 18, 12, 23, 25 and 15

12. Pin and Bushing Wear

Drops .................................................................................... 1 and 4, 2 and 3, and 11

13. Low Cushion/Carbonaceous Material

14. High Cushion/Carbonaceous Material

Porosity ........................................................ 20, 1, 4, 10, 9, 26, 22, 15, 28, 7 and 21

Hot tears ................................................................................. 1, 4, 15, 21, 22 and 26
Warpage .......................................................................................... 2, 3, 11, 5 and 16

15. Hard Molds or Cores

16. Uneven Mold Hardness
17. Mold Wall Movement
18. Pattern Problems

Veining ................................................................. 13, 1, 16, 2, 28, 20, 17, 15 and 21

19. Insufficient New Sand

Rat-Tails ........................................................... 13, 1, 16, 2, 4, 28, 20, 27, 15 and 21

20. Lack of Mold Vents

Shrink ........................................................................ 17, 5, 18, 11, 26, 22, 21 and 28

21. Excessive Metal Temperature

22. Gating

Buckles ............................................................. 13, 1, 16, 2, 4, 18, 20, 17, 15 and 21

23. Build up on Flask

Erosion Scabs ......................................................... 1, 5, 14, 9, 22, 19, 24, 21 and 28

24. Hot Sand

Swells .................................................................................. 5, 1, 11, 17, 4, 28 and 16

25. Improper Coresetting

26. Melt Analysis

Pin Holes ...................................................... 20, 1, 4, 10, 9, 26, 22, 15, 28, 7 and 21

27. Contaminated Sand

Penetration ...................................................................... 20, 21, 1, 4, 5, 19, 24 and 8

28. Wrong Preblend or Mixture

Download these tables at www.moderncasting.com

38

modern casting / September 2000

Cracked Molds

Mold Sticker

Backup
Sand
Facing
Sand

Cracks in molds initiate at the surface of the mold cavity and

extend through the zones of least resistance in the mold. The
result is the formation of large thin fins in planes related to
the position of the casting in the mold. Cracked molds can be
due to pattern problems, equipment problems, oversized
cores, low methylene blue clay, coresetting and/or low sandto-metal ratio.

High-Density Molding Problems

Mold stickers are an irregular massive projection on the cope

surface of the casting with an appearance that suggests detachment of a part of the mold wall. This mold problem usually is
accompanied by sand inclusions or missing material embedded
in the casting surface. Mold stickers can be due to hot sand,
high moisture, low methylene blue clay, poor pattern spray
application, equipment problems, pattern problems, low
mositure, and/or wrong preblends or mixture.

Causes

Cracked Molds ........................................................................ 12, 10, 8, 4, 15 and 17

Ram-Away ............................................................................................ 12, 1, 4 and 3
Push-Ups ........................................................................................ 10, 12, 8, 4 and 1
Sagging ......................................................................................... 12, 10, 4, 1 and 16
Stickers ........................................................................... 13, 1, 4, 14, 10, 12, 2 and 6
Friable Edges ............................................................................ 13, 2, 3, 12, 4 and 10
Sand Stickers in Hoppers ................................................................. 1, 4, 3, 13 and 6
Run-Outs ............................................................ 9, 11, 12, 10, 8, 5, 15, 18, 1 and 17
Shakeout Problems ................................................................................ 3, 1, 6 and 7
Losing Sand at Shakeout ................................................................... 1, 4, 3, 7 and 6
Hot Sand ....................................................................................... 10, 16, 7, 17 and 4
Short Sand Volume ............................................................................... 1, 4, 10 and 3

Causes
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

High Moisture
Low Moisture
High Methylene Blue Clay
Low Methylene Blue Clay
Poor Squeeze
Wrong Preblend or Mixture
Insufficient New Sand
Oversize Cores
Sand on Flask Flanges
Equipment Problems
Pin and Bushing Wear
Pattern Problems
Hot Sand
Pattern Spray
Coresetting
Insufficient Sand
Low Sand-to-Metal Ratio
Low Joints

Pinholes

Sand Inclusions

Pinholes are small cavities (often the size of the head of a pin)
located in extended colonies across the casting surface. The
molding-related causes of pin holes can include: a lack of mold
venting, high moisture in the mold, low methylene blue clay
and/or excessive pattern spray.

Sand inclusions in a casting are usually compact and occur in

the vicinity of the cope surface of the casting. Often they are
visible on the rough casting, but may appear only upon machining. The molding-related causes of sand inclusions can include:
low mold moisture, high or low methylene blue clay, gating
problems, wrong preblend and/or sand mixture.

modern casting / September 2000

39