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.

Casting Defects

Surface defects

Internal defects

Incorrect chemical compo.

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.

FINS OR FLASH

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.

Continue
Increase permeability of sand and check
grinding.
Warm densors and chills.
Modify gating to reduce turbulence, use
sivex filter.

Gas

HOLE

 Next

Member
Waqar Sarwar

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.

Shrinkage cavity

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.

Hot Tears

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton

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