S&B Industrial Minerals GmbH
Burn on Broken Mould
Nature of Defect
Thin sand crusts firmly
adhering to the casting.
Defect occursmore frequently
with thickwalled castings at
high castingtemperature.
Remedies
Increase amount of lustrous
carbon producers and coke pro-
ducers in the moulding sand.
Increase amount of new sand
if sintering point of the sand is
low and oolitization is high.
Explosion Penetration
Nature of Defect
Extensive penetration, when
the mould is filled too quickly.
Remedies
Reduce amount of free water.
Increase milling time of the
moulding sand. Increase ooliti-
zation rate of the moulding
sand.
Moulding Sand
Micro Shrinkage
Nature of defect
Porous structure found in the
area of the casting which is last
to solidify.
Remedies
Defect occurs with alloys having
a wide solidification range.
Little influencing by the moul-
ding sand. Reduction of organic
material and an increase in the
moisture level will improve
thermal conductivity of the
moulding sand.
Penetration
Nature of Defect
Roughness caused by the
molten metal penetrating the
immediate sand grains of the
mould surface, particularly in
softly rammed areas.
Remedies
Use finer sand. Improve ram-
ming of the moulds. Reduce
compactability of the moulding
sand. Increase amount of
carbonaceous additive. Increase
amount of coke in the moul-
ding sand.
Sand inclusions
Nature of Defect
Irregularly formed sand
inclusions just underneath the
casting surface, associated with
products from the metal slag
reaction in other areas.
Remedies
Keep the moulding sand suffi-
ciently plastic by good sand
preparation and sand cooling.
Adjust to optimum compac-
tability. Reduce the tendency
of the mould to stick to the
pattern by the use of parting
agents.
Swells
Nature of Defect
Irregular bulges, in most cases
widely spread, sometimes with
rough surface and/or pene-
tration.
Remedies
Reduce compactability of the
moulding sand. Ram moulds
better and more evenly.
Make sand less sensitive to
over- and underramming by
increasing the amount of
bentonite.
Erosion
Nature of Defect
Flash-like metal penetration in
the mould, sometimes parts of
the mould are included in the
casting.
Remedies
Add more bentonite to increase
green tensile strength.
Raise compactability of the
moulding sand.
Lustrous Carbon Inclusions
Nature of Defect
Formation of surface irregula-
rities, inclusions and laps due
to non-wetting characteristic of
lustrous carbon, often associ-
ated with the use of Cold-Box
cores.
Remedies
Use dried Cold-Box cores.
Reduce amount of lustrous
carbon producer in the
moulding sand. Use carbon-
aceous additive with a higher
coking residue.
Scarred Surface
Nature of Defect
Scarred casting surface around
hot spots, particularly with SG
cast iron.
Remedies
Reduce amount of impurities
present in the sand that are
destroying the oxide skin.
Pin Holes
Nature of Defect
Accumulation of small sub-
surface rounded holes.
Defects appear after annealing
and light machining.
Remedies
Normally the defect is of a
metallurgical nature.
The mould material may have
a certain effect. In case of pin
holes the moisture, the organic
additions and the amount of
nitrogen in the moulding sand
should be reduced.
Slag inclusions
Nature of Defect
Non-metallic irregular shaped
inclusions, when occurring,
tend to be on upper casting
surfaces.
Remedies
The defects are caused by
slag being present with the
molten metal in the pouring
ladle. If the formation is due
to eroded sand, reduce the
amount of inert fines and use
a more active lustrous carbon
producer. Increase milling time
of the moulding sand.
Metal Penetration
Nature of Defect
Firmly adhering agglomerates
of sand/metal at hot spots and
in softly rammed areas.
Remedies
Reduce compactability of the
sand. Improve ramming of the
moulds. Increase amount of
carbonaceous additive and coke
in the moulding sand.
Nature of Defect
The sand is washed away,
mostly near to the sprue, often
accompanied by sand inclu-
sions. Bulges arise on the
casting near to the gate.
Remedies
Avoid drying out of the moul-
ding sand. Increase amount of
bentonite in the sand. Increase
milling time of the moulding
sand. Increase mould com-
paction. Use carbonaceous
additive with a high lustrous
carbon producing ability.
Fissure Defect
Nature of Defect
Narrow, crack-like cavities
vertical to the surface. Dendrite
formation in the cavities.
Remedies
The defect is of a metallurgical
nature due to too much nitro-
gen contained in the iron.
Reduce the amount of nitrogen
in the moulding sand. Use low
nitrogen containing carbon-
aceous additive. Reduce
addition of carbonaceous
additive in the moulding sand.
Blow Holes
Nature of Defect
Cavities with smooth walls,
singularly or in groups.
Remedies
Low casting temperatures are
often the cause. Benefits may
be obtained by increasing
mould permeability.
Reduce fines or add coarser
new sand. Reduce organic
additions to the sand.
Roughness
Nature of Defect
Rough casting surface finish
due to coarse sand.
Remedies
Use finer sand. Increase amount
of lustrous carbon producing
material in the moulding sand.
Increase the amount of fines
e.g. coke in the sand.
Scabs
Nature of Defect
Mushroom type defect with
sharp edges parallel to the
casting surface.
Remedies
Increase bentonite level.
Use carbonaceous additive with
a wide softening range.
Increase the amount of
carbonaceous additive in the
moulding sand.
Blow Holes at Angles
Nature of Defect
Smooth wall cavities at the
angles of the casting.
Remedies
The cause is insufficient feeding
and rate of solidification.
Influencing by moulding sand
is possible. Reduce the moisture
content and the organic
additions of the sand.
Improve the venting of the
mould.