MANUFACTURING

PROCESSES
ASSIGNMENT #2
CASTING DEFECTS
&
REMEDIES
SUBMITTED BY:
Yashvinder Singh (111501)
Sahil

(111502)
Section - H1

INTRODUCTION
Metal casting is one of the direct
methods of manufacturing the desired
geometry of component. The method is also
called as near net shape process. It is one of
the primary processes for several years and
one of important process even today in the
21st century.
Out of the several steps involved in the
casting process, moulding and melting
processes are the most important stages.
Improper control at these stages results in
defective castings, which reduces the
productivity of a foundry industry. Generally,
foundry industry suffers from poor quality and
productivity due to the large number of
process
parameters, combined with lower penetration
of manufacturing automation and shortage of
skilled workers compared to other industries.
Also, Global buyers demand defect-free
castings and strict delivery schedule, which
foundries are finding it very difficult to meet.

Casting process is also known as process

of uncertainty. Even in a completely controlled
process, defects in casting are found out
which challenges explanation about the cause
of casting defects. The complexity of the
process is due to the involvement of the
various disciplines of science and engineering
with casting. The cause of defects is often a
combination of several factors rather than a
single one. When these various factors are
combined, the root cause of a casting defect
can actually become a mystery. It is important
to correctly identify the defect symptoms
prior to assigning the cause to the problem.
False remedies not only fail to solve the
problem, they can confuse the issues and
make it more difficult to cure the defect. The
defects need to be diagnosed correctly for
appropriate remedial measures, otherwise
new
defects
may
be
introduced.
Unfortunately, this is not an easy task, since
casting process involves complex interactions
among various parameters and operations
related to metal composition, methods

design, molding, melting, pouring, shake-out,

fettling
and
machining.
The
proper
classification and identification of a particular
defect is the basic need to correct and control
the quality of casting.

LIST OF DEFECTS
01. Shrinkage
02. Cold Shut
03. Mismatch
04. Blow holes
05. Pin Holes
06. Fin
07. Drop
08. Swell
09. Metal Penetration
10. Hot Tears
11. Porosity
12. Scabs
13. Hard Spots
14. Buckles\Rat Tails
15. Misrun

SHRINKAGE
Shrinkage cavity is a void on the surface
of the casting caused mainly by uncontrolled
and haphazard solidification of the metal.

Causes:
-inadequate and improper gating

-poor design of casting involving

changes in thickness

abrupt

-too high pouring temperature

Remedies:
-Use the suitable composition that is adjusted
silicon and (1.80 to 2.10) or carbon equivalent
(3.9 to 4.1) .Carry out proper ramming and
maintain optimum pouring temperature and
time.

Cold Shut
When two streams of molten metal approach
each other in the mould cavity from opposite
directions but fail to fuse properly, with the
result of discontinuity between them, it is
called a cold shut.

Causes:
-low temperature of molten metal
-improper gating system
-too thin casting sections
-slow and intermitted pouring
-improper alloy composition
-use of damaged pattern

Remedies:
- Smooth pouring with the help of monorail.
- Properly transport mould during pouring.
- Arrange proper clamping arrangement.
-providing appropriate pouring temperature.

Mismatch
It is a shift /misalignment
between two
mating surfaces or the top and bottom parts
of the casting at the mould joint.

Causes:
-worn dowel in patterns made in halves.
-improper alignment of mould boxes due to
worn out/ill fitting mould boxes.

Remedies:
- Properly arrange box warpage.
- Properly move boxes with pins.
- Properly clamp the boxes.

Blow Holes
Balloon-shaped gas cavities caused by
release of mould gases during pouring are
known as blow holes.

Causes:
-ramming is too hard.
-permeability is insufficient.
-venting is insufficient.

Remedies:
-moisture content of moulding sand should be
controlled
-sand of appropriate grain size should be
used.
-ramming should not be too hard.
-moulds should be adequately vented.

Pin Holes
Pin holes are tiny blow holes appearing just
below the casting surface.

Causes:
-sand with high moisture content.
-absorption of hydrogen/carbon monoxide gas
in the metal.
-alloy not being properly degassed.

-steel is poured from wet ladles.

-sand containing gas producing ingredients.
Remedies:
-reducing the moisture content of moulding
sand.
-increasing its permeability.
-employing
practices.

good

melting

and

-improving a rapid rate of solidification.

fluxing

Fin
Fins are excessive amounts of
metal created by solidification into
the parting line of the mold

Causes:
-inadequately weighted sand as well
incorrectly assembled moulds and cores.

as

-over flexible bottom boards.

-loose plates and improper clamping of flasks.

Remedies:
-correct assembly of the mouldand cores used
for casting.

Drop
Drop is an irregularly-shaped projection
on the cope surface caused by dropping of
sand.
Causes:
-low
green
moulding

strength of the
sand.

-low mould hardness.

-insufficient reinforcement of sand projections
in the cope.
Remedies:
-moulding sand should have sufficient green
strength.

-ramming should not be too soft.

Swell
Swells are excessive amounts of
metal in the vicinity of gates or beneath
the sprue

Causes:
-insufficient or soft ramming.
-low mould strength.

-mould not being adequately supported.

Remedies:
-sand should be rammed evenly and properly.

Metal Penetration
Penetration occurs when the molten
metal flows between the sand particles in the
mould. These defects are due to inadequate
strength of the mold and high temperature of
the molten metal adds on it.

Causes:
-low strength of moulding sand.

-large size of moulding sand.

-high permeability of sand.
-soft ramming.

Remedies:
-use of fine grain with low permeability.
-appropriate ramming.

Hot Tears
A hot tear is a fracture formed during
solidification
because
of
hindered
contraction.

Causes:
-faulty casting design leading to excessive
stresses at certain portions in the casting.
-very hard ramming.
-too much shrinkage of molten metal.
-incorrect pouring temperature.
-improper gates and risers.
-low flowability of molten metal.
-high sulphur content in molten metal.
Remedies:
-ramming should not be too hard.

-modification in pattern to take care of

residual stresses.

Porosity
Porosity is pockets of gas inside the
metal caused by micro-shrinkage during
solidification.

Causes:

-dissolved hydrogen and sulphur dioxide in

molten metal.
-excessive poring temperature.
-slow rate of solidification.
-high moisture content of the mould.

Remedies:
-maintenance of proper melting temperature.
-casting should be made to solidify quickly by
using proper gating and risering.
-permeability
increased.

of

the

mould

should

be

-moisture content of mould should be kept

low.

Scabs
Scabs are surface slivers caused
by splashing and rapid solidification of
the metal when it is first poured and
strikes the mold wall

Causes:
-insufficient strength of mould and core.
-uneven mould ramming.
-lack of binding material in facing as well as
core sand.
-Faulty gating.
-intense local heating due to slow running of
molten metal over sand surface.
Remedies:
-appropriate ramming.
-improved gating system.

-addition of sufficient binders in facing and

core sands.

Hard Spots
These spots are formed due to the local
chilling by moulding sand which leads to the
formation of white cast iron at those places,
rendering them hard.

Causes:
--faulty metal composition.
-faulty casting design resulting in relatively
more rapid cooling of certain spots.
Remedies:
-modification of casting design.
-modification of casting composition.

Buckles/Rat Tails
Rat tail or a buckle is a long, shallow,
angular depression caused by expansion of
the sand.

Causes:
-excessive mould hardness.
-lack of combustible additives in the moulding
sand.
-continuous large surfaces on the casting.

Remedies:
-suitable addition of combustible additives to
moulding sand.
-reduction in mould hardness.
-modifications in casting design.

Misrun
When the molten metal fails to fill the
entire mould cavity before the metal starts
solidifying , resulting in an incomplete casting,
the defect is known as misrun.

Causes:
-low temperature of molten metal
-improper gating system
-too thin casting sections
-slow and intermitted pouring
-improper alloy composition
-use of damaged pattern

Remedies:
_ Smooth pouring with the help of monorail.
_ Properly transport mould during pouring.

_ Arrange proper clamping arrangement.

-providing appropriate pouring temperature.