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Green Sand Casting Defect!: Name
Green Sand Casting Defect!: Name
Name… That…
Green Sand Casting Defect!
Foundrymen often are stumped by the origin of casting
defects. To aid in the analysis, this article explores common
green sand defects, their causes and possible remedies.
Ian Kay and Mark Nagel, Cast Metals Institute (CMI), Des Plaines, Illinois
Alfred T. Spada, Executive Editor
asting defect recogni- temperature is less than 212F
tion is one of the most (100C), it re-condenses, creating
difficult tasks facing a a wet layer. This wet layer is
metalcaster. With the multitude weaker than the normal green
of processes (coremaking, mold- sand or the hot, dry sand layer
ing, melting, etc.) used to manu- directly beneath the metal. As the
facture a casting, determining hot sand expands, the wet layer
which is responsible for a defect shears to allow the expan- sion.
requires analysis, testing and, most The small ridge of sand that
importantly, experience. extends into the mold cavity as a
Of all the departments within a result of the expansion can cre-
foundry, more defects can be at- ate a line on the surface of the
tributed to molding and the sand casting called a rattail (Fig. 1).
system than any other. This is due This defect usually is formed on
in part to the high number of com- Fig. 1. RATTAIL—Caused by expansion, it is a small ridge the drag portion of the casting.
ponents that make up a green of sand that extends into the mold cavity and makes an In further filling of the mold
impression on the casting surface.
sand mold. From the sand, clay cavity, the molten metal radiates
and water to the carbon, cereal and other additives, each heat toward the cope casting surface. The moisture on this
component has properties that serve to reduce or control surface vaporizes and permeates into the sand where it
specific defects in castings. However, when the amount of condenses to form the wet layer. In the same manner as in the
any one component is out of balance with regard to the drag portion of the mold, as the molten metal nears the cope
casting being poured, the potential for defects arises. surface of the mold, the intensity of the radiant heat increases
This article will examine the causes of common green sand and the sand in the dry sand layer expands. The wet layer
casting defects related to expansion, metal penetration, gas and splits or shears to accommodate this expansion.
weak sand while offering possible remedies. Although every As the metal completes the filling of the mold cavity, the
casting operation is different, common themes tie many of sand buckles, creating a deep groove on the casting surface
these defects together, allowing a foundry to follow a simple called a buckle (Fig. 2). Sometimes the buckle will open up,
step-by-step remedy progression to determine which area(s) allowing the metal to run through the crack in the sand and
of mold development is responsible for the defect. fill the void behind the buckle to create a scab (Fig. 3).
Although the rattail is synonymous with the drag and the
Expansion Defects buckle and scab with the cope, the three expansion defects
Expansion defects are a family of defects that include may be found on either casting surface. When foundries are
rattails, buckles and scabs. These faced with these defects, the fol-
defects originate, in part, from the lowing remedy progression should
expansion of the sand gains when be applied to the sand system:
heated by the metal entering the • make an addition of cellulose or
mold. Silica sand expands the great- cereal to the sand to provide a place
est amount when in contact with for expansion to occur;
the molten metal, as compared to • lower the moisture content of the
olivine, chromite and zircon sands, molding sand, which increases
which expand less. the overall mold strength;
Beyond sand expansion, these • lower the pouring temperature of
defects also are moisture related. the metal (eliminate excess super-
As molten metal runs over the sur- heat), which reduces the amount
face of a green sand mold, moisture of sand expansion;
in the sand is converted to steam • lower the temperature of the mold-
that permeates between the sand Fig. 2. BUCKLES—Due to a weak wet layer in the mold, ing sand from the return sand sys-
grains. When the steam reaches a the sand can buckle and form a deep groove on the tem to increase the strength prop-
point in the mold where the sand casting surface. erties of the sand;
modern casting / September 2001 29
AFS Library Copy: 20020203A.pdf, Page 1 of 4 Pages, Provided to User for Internal Use and Not Public Redistribution or Resale.
Copyright © 2002 American Foundry Society.
• increase the clay content of the contacts the mold surface, it
sand, especially sodium quickly loses heat and a thin,
(western) bentonite, for better solid skin forms against the
hot strength properties; mold. This skin prevents mol-
• improve the sand distribution ten metal from penetrating into
to at least three screens to stag- the voids between the sand
ger the expansion and create grains. When metal is poured at
a linear expansion curve; higher temperatures, the extra
• decrease the amount of fines heat in the metal diffuses into
in the sand. Fines tend to soak the sand, delaying the skin for-
up water, increasing overall mation. Without the rapid for-
mold moisture without increas- mation of the skin, molten metal
ing mold strength; has more time to penetrate into
• avoid over-ramming or over- the sand, creating the defect.
squeezing the mold. This Chemical Reaction—In this
pushes the moisture closer to Fig. 3. SCAB—Sometimes the buckle in the sand will mechanism, a reaction occurs
the mold surface, increasing between the liquid metal and
the probability for defects; the sand and fill the void behind the buckle to create a the molding material. These re-
• improve the sand mulling prac- scab defect. actions may produce products
tice to create a more homog- that act as glue, adhering the
enous sand mixture with better de- molding sand to the casting.
veloped bond; This reaction usually is limited to
• fill the mold faster by increasing ferrous alloys (especially steel).
the flow rate of the gating system When these alloys are exposed to a
to leave less time for the heat to source of oxygen (O) such as air or
act on the sand without pressure water, the O may react with the iron
from the metal. (Fe) in the ferrous alloy to form iron
oxide (FeO), also called wustite.
Adhering Sand Defects Once formed, FeO can react with
Adhering sand defects are com- silica to form iron silicate or fayalite.
mon to all alloys poured in green Fig. 4. BURN-ON—This defect usually can be This is a liquid at metal pouring tem-
sand and are characterized by a removed during shotblasting. perature that easily wets the surface
rough casting surface or by sand stick- of the silica and runs between the
ing to the casting surface. These de- sand grain. Fayalite then solidifies
fects may be found at a specific spot around the grains, gluing the sand
on the casting such as a hot spot or onto the surface of the casting.
over the entire casting surface. Two The defect has two different
of the most common ways these de- forms—burn-on and burn-in. The
fects are produced are mechanical difference is how tight the sand is
penetration and chemical reaction. adhering to the casting surface,
Mechanical Penetration—This is which is a result of how fast the sili-
the penetration of metal into the mold cate cools as it is being formed. Burn-
material due to the metallostatic pres- on (Fig. 4) sand isn’t held as tight
sure of the molten metal. It usually is and usually can be removed during
seen when the sprue height is too shotblasting. Burn-in usually requires
large. The greater the height of the a grinding operation to remove it, if
metal in the mold from the top of the it can be removed at all.
pouring cup to the bottom of the cast- Remedies for sand-adhering de-
ing, the greater the pressure exerted fects include:
on the liquid. High metal pressures • reduce the moisture content of
force molten metal between the sand the sand because the moisture fills
grains where the metal solidifies, hold- the space between the sand grains.
ing sand on the casting surface. Fig. 5. BLOWS—A gas defect, it is denoted by When the moisture evaporates af-
Mechanical penetration also can large voids in the casting due to entrapped, ter being hit by molten metal, it
soluble or reactive gas.
occur where the metal impinges on then leaves open space for the
the mold wall. This dynamic pres- metal to penetrate;
sure of the metal can force it into the sand grain openings. • improve mold compaction to increase density and leave less
This often occurs near the gate entrances to the casting. High room for the metal to penetrate;
metal velocities found at the gates can produce the pressure • reduce metal velocity because higher velocities create more
necessary to create penetration defects. pressure, allowing the metal to penetrate more easily;
Two factors that affect mechanical penetration are the sand’s • improve casting design and avoid metal re-entrant angles.
fineness and the metal pouring temperature. In general, the Sharp internal corners create hot spots, which are areas
coarser the sand, the larger the voids between the sand grains. where penetration is more likely occur;
It takes less pressure to force metal into larger voids. • reduce the metallostatic head pressure because the higher
In regard to pouring temperature, when the molten metal the pressure, the easier metal can penetrate the mold wall;