Cold Shut / Misrun defect in

Alumunium Casting

Rudiyansah
0806331973
Teknik Metalurgi dan Material
Universitas Indonesia
 Misrun/ Cold Shut
Misruns merupakan suatu cacat yang terjadi
karena logam cair tidak mengisi seluruh
rongga cetakan sehingga benda cor menjadi
tidak lengkap atau ada bagian yang hilang
 Misrun defect

Example of misrun defect

 Cold Shut and Misrun
• Probable Cause
a. Poor poring practice
b. Improper gating
c. Low shell permeability
d. Low metal fluidity
e. Low metal or mold temperature
f. Ketidakseragaman dimensi benda cor, mengganggu aliran dari logam
cair
g. Lubang angin yang kurang pada cetakan
h. Coating terlalu tipis
i. ukuran,penempatan dan distribusi saluran masuk, runner dan sprue
tidak sesuai
 Cold Shut and Misrun
• Suggested Cure
a. Increas metal and/or mold temperature
b. Increase head pressure and/or rate of pour; avoid splashing
c. improve gating to enhance mold fill
d. Modify alloy composition to enhance fluidity
e. Increase permeability by using coarse refractory flour (200
mesh for primary, 120 mesh for backups)
f. Insulates the mold or use an insulating refractory (Alumina
bubbles)
g. lubang angin (ventilasi) harus ditambah
 Comparison of filling sequences, with and without
misrun, in Alumunium Motor Rotor in Die casting

• Numerical analysis result without misrun (Core length 700mm, slot width 9mm, slot length
25.5mm)
 Comparison of filling sequences, with and without
misrun, in Alumunium Motor Rotor in Die casting

• Numerical analysis result with misrun (Core length 700mm, slot

width 7.6mm, slot length 18.8mm)
Misrun defect in Alumunium motor rotor
(Hyundai Heavy Industries)
Misrun defect in Alumunium motor rotor
(Hyundai Heavy Industries)
Surface defect of semi-solid die casting of ADC 12 Alumunium alloy
 Misrun defect in intercooler of radiator
assembly, which is used in buses and trucks
 Continued (Prevention)
• To minimize the misrun defect in intercooler
assembly, several parameter process must be
kept in controlled. Such as :
Fluid flow behaviour, gating and feeding
design, flows breaks between riser and
casting, hot spot area
 Continued (prevention)

Actualization of intercoolar assembly condition with gating system and

risers
 Continued (prevention)

• Simulation with ProCAST, to predict fluid flow behaviour in

casting process
 Continued (prevention)
• Problems that occurred and must be evaluate to minimize the
misrun
Continued (prevention)
Continued (prevention)
Continued (prevention)
Continued (prevention)
Safe band for operating DIE, in intercooler
assembly process
 References
Bambang Suharno.Diktat kuliah Pembentukan Logam.FTUI
http://www.foundryinfo-india.org/tech_section/pdf/15_OP.pdf
http://www.me.gatech.edu/jonathan.colton/me4210/castdefect.pdf
http://www.foseco.com.tr/tr/downloads/FoundryPractice/235-
03_Using_the_SEM_for_defect_analysis.pdf
http://www.indianfoundry.org/docs/paper_4_jan11.pdf
http://www.springerlink.com/content/pmc0lej1fw6xc9wl/
http://www.ysxbcn.com/upfile/soft/201099/33-p1756-4163.pdf
http://www.wpi.edu/Pubs/ETD/Available/etd-1223102-
102625/unrestricted/ziolkowski.pdf
http://www.ifme.eu/scopi/group/foundry/foundry.nsf/pagesref/SBDD-
7MDMSB?Opendocument&lang=en