CASTING DEFECTS

Submitted by
Vineeta Kanwal ID NO - 44316

Classification of defects
Defects caused by patterns and moulding box equipment. Defects due to improper moulding and core-making materials. Defects due to improper sand mixing and distribution. Defects caused by moulding, core making, gating etc. Defects due to improper mould drying and core baking. Defects occurring while closing and pouring the moulds. Defects caused by molten metal. Defects occurring during fettling etc. Defects due to faulty heat treatment. Defects due to cast metal. Warpage.

Defects caused by patterns and moulding box equipment

Mismatch or mould shift Variation in wall thickness of the casting Fins, flash and strain Crush

Mismatch or mould shift

Causes the dislocation at the parting line. Carelessness in placing the cope on the drag. Inaccurate pattern dowel pins. Loose box pins

Variation in wall thickness of the casting

Causes due to Worn core boxes Worn core prints Inadequate core print area

Fins, flash and strain

Occur at the parting line Straining makes casting thicker than pattern Due to patterns having insufficient taper Top part boxes inadequately weighted

Crush
Displacement of sand while closing a mould Irregular sandy depression in the casting Coreprint with too little clearance Excessive weight of cope portion

Defects caused due to improper moulding and core making materials

Blowholes Drop Scab Pin-holes Metal penetration and rough surface Hot tears

Blowholes
Smooth and round holes Location always in the upper part of the castings and beneath cores or undercuts Occur due excessive moisture, presence of gas producing ingredients, inadequate venting and low permeability of the mould

Drop
Occurs when cope surface cracks and breaks Due to low green strength Low mould hardness Insufficient reinforcement of sand projections in the cope

Scab
Rough, irregular projections on surface of castings containing embedded sand Occurs when a portion of the face of a mould or core lifts and metal flows underneath in a thin layer Caused by using too fine sand grains or using sand of low permeability or moisture content or uneven mould ramming or by intense local overheating

Pin-holes
Small holes revealed on the surface of a casting after the surface has been cleaned by shot blasting Due to sand with high moisture content, faulty metal Gas dissolved in alloy and not being properly degassed

Metal penetration and rough surface

Molten metal enters into the space between the sand grains Due to high permeability Large grain sized sands Low dry strength of sand Soft ramming

Hot tears
Ragged irregular internal or external cracks occurring immediately after the metal have solidified Due to poor collapsibility of cores, too much shrinkage of metal while solidifying High sulphur content Too low pouring temperature

Defects due to improper sand mixing and distribution

Give rise to faulty sand conditions and defects like Blowholes Drop Scab Pin-holes Metal penetration and rough surface Hot tears

Defects caused by moulding, core making, gating etc

Hot tears Shifts Fins and flash Crush Cold laps (shuts) and misrun Slag holes Shrinkage defects

Cold laps (shuts) and misrun

Is caused when the section thickness of a casting is so small or the pouring temperature so low that the entire section is not filled before the metal solidifies Is caused when two streams of metal which are too cold meet but do not fuse together.

Slag holes
Smooth depressions on the surface of castings Usually occur near the ingates Due to slag that enters in mould cavity Slag traps should be inserted in the gating system

Shrinkage defects
Caused by improper directional solidifications, poor gating and risering design and inadequate feeding Solidification leads to volumetric contraction which must be compensated by feeding Surface shrinkage or internal shrinkage defects are produced making the casting weaker

Defects due to improper mould drying and core baking

A layer of moisture collected under the impervious layer of mould paint causes sand washes, scabs, blowholes Oil sand cores, if over-baked cause sand washes, rough surface, metal penetration, undersized holes Oil sand cores, if under-baked cause core sand wash, core blow, blow holes

Defects occurring while closing and pouring the moulds

Shifts or mismatch Misrun Cold laps or cold shuts Crush Run out Inclusions

Run out
During the casting, metal runs out of the box at the parting Casting is incomplete or fully missing The upper part of a casting is mostly missing Due to faulty moulding

Inclusions
Foreign materials present in the cast metal. In the form of oxides, slag, dirt, sand or nails. Sand cracked and broken from gating system, mould cavity, cores etc Reduced by using correct grade of moulding sand and proper skimming to remove impurities.

Defects caused by molten metal

Misruns Cold shuts Excessive penetration Tin and lead sweat Hot tears Sand cuts and washes Fusion Gas porosity, gas holes, sponginess Shot metal Rattails and buckles Swell

Tin and lead sweat

Occurs in high leaded copper-base alloys as spots and lumps The surface of the casting is covered with protusions of white metal Due to high pouring temperature, gassy metal, knocked out too quickly

Sand cuts and washes

Cuts and washes are caused by erosion of mould and core surfaces by the metal flowing in the mould cavity. These defects are avoided by proper ramming, having sand of required strength and controlling the turbulence during pouring.

Fusion
Thin sand crusts firmly adhere to the casting Rough cast surface Sand sintered on the casting, which can only be removed by grinding Using sand of enough refractoriness and pouring at suitable temperature can eliminate this defect.

Gas porosity, gas holes, sponginess

Hydrogen is responsible for gas porosity Gas holes are caused by hydrogen and sulphur dioxide in non ferrous castings and by oxygen in ferrous Due to excessive high temperature, damp ladles, low permeability of sand, slow solidification rate Remove the dissolved gases from the melt

Shot metal
Shots embedded in the casting Excessive sulphur content in the molten metal Higher moisture content of the moulding sand Faulty gating system Improper pouring of molten metal

Rattails and buckles

Caused by the expansion of a thin outer layer of moulding sand on the surface of the mould cavity due to metal heat. A rat tail is caused by depression of a part of the mould under compression which appears as an irregular line on the surface of the casting. A buckle is a more severe failure of the sand surface under compression. The mould must provide for proper expansion instead of forming compressed layers to avoid this defect.

Swells
Enlargement or bulging of the casting surface resulting from liquid metal pressure. Due to poor ramming of the mould or not properly reinforcing deep moulds. Avoided by proper ramming of the sand and providing adequate support to the mould.

Defects occurring during fettling etc

Sand and scale not properly removed Distorted castings not properly straightened Chisel marks left on the casting Cracks caused in brittle castings by too heavy grinding

Defects due to faulty heat treatment

Uncontrolled initial heating may cause cracking of brittle castings Careless stacking of casting while they are in a semi plastic state tend them to distort Fast cooling rates may develop cracks Improper heat treatment furnace atmosphere may prove detrimental to the surface appearance of the castings

Defects due to cast metal

Hard spots Hard spots are caused by chilling action of moulding sands in some metals like gray cast iron with insufficient silicon. These spots are extremely hard and often lead to machining difficulties. Hard spots are avoided by providing uniform cooling and pouring at the right temperature.

Warpage
Surface of mould part do not follow the intended shape of the design. Results from residual stresses, caused by differential solidification rates

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