DEFECT 1

VEINING: DEFECT PATTERN & CAUSES

Veining is a typical form of defect that occurs in organically bonded mold parts, i.e. a defect that is
found in cores very frequently. It results from the formation of a shell, which forms a vein-like crust.
The defect appears as thin, irregular metallic protuberances.
Core with veining
Veining forms as a result of the silica expanding into the mold cavities, which causes the casting
metal to fill in the resulting gap and form a vein-like crust.
Veining can occur in all foundry materials. Cast iron with nodular graphite, malleable cast iron and
bronzes containing lead are particularly prone to veining, whereas aluminum and magnesium alloys
are less prone to veining.
Veining that is caused by cores appears as irregular, fine, thin metallic protuberances in angles or at
corners and edges of the cast parts. Veining leads to an increased level of rework and, in some
cases, to rejections.
Veining is likely to occur on the inner contours (cores) of the cast parts when chemically hardened
mold materials are used. Its formation is caused by cracks in the surface of the mold part that can be
penetrated by the liquid metal.
Binders and additives are crucial
Since veining must primarily be attributed to the heat-induced expansion of the mold materials, mold
parts made of silica sand are particularly at risk. The liquid metal that surrounds the core causes a
temperature gradient between the surface and the center of the core, which leads to stress.
Up to approx. 400°C, silica sand expands linearly and then displays an abrupt increase in the
temperature range of the reversible ß-conversion (Figure 3), which increases the stress.
Veining is also influenced by the high-temperature behavior of the binder (hot tensile strength,
thermoplasticity) and possible additions and also by the wettability and thermal conductivity of the
mold material.

Factors that influence the formation of veining

 Grain size and grain particle size distribution (a higher degree of uniformity leads to higher stress,
since all silica grains pass through the conversion temperature simultaneously.)
 Intensity of compaction (the higher the intensity of compaction, the higher the packing density, which
increases the stress.)
 Molding base material (influences the tendency toward defects via the height and uniformity of
expansion and the thermal conductivity.)
 Casting temperature (high casting temperatures cause a quick silica conversion and thus lead to
increased stress in the mold part.)
 DEFECT PREVENTION
The formation of veining is caused by cracks in the surface of the mold part that can be penetrated
by the liquid metal. A number of measures have proven effective in the prevention of veining, and
the most important ones are listed below.

An overview of the key measures for preventing veining

 Homogeneous distribution of the silica conversion of the entire particle size range by using sand with
a low degree of uniformity
 Reducing the intensity of compaction
 Using a molding base material with higher thermal conductivity, which leads to a smaller stress
difference in the grain bond and to faster solidification
 Using mold material additions (mineral or organic additives) from the extensive ASK Chemicals
product range of additives
 Using suitable coatings
 Using suitable binders

PRODUCT SOLUTIONS
Veining is influenced by the high-temperature behavior of the binder, e.g. its thermoplasticity or hot
tensile strength. The liquid metal that surrounds the core causes a temperature gradient between the
surface and the center of the core. This involves stress that develops as a result of structure-related
expansion processes of the molding base material (usually silica sand).
ASK Chemicals offers the following solutions with regard to products and
expertise:
 Performing analyses of the molding sand to determine the degree of uniformity, which should be low
 Transferring expertise in the consistent selection of the correct resins for the respective case of
application
 Using mold material additions, i.e. mineral-based and organically based additives, for the production
of cores
 Highly effective and highly refractory alcohol- and water-based coatings – depending on the molding
base material, the binder and the material
 Transferring expertise in the optimization of the possible molding base materials.

DEFECT 2
Buckle:
A buckle is a long, fairly shallow, broad, vee depression that occurs in the surface of flat castings. It
extends in a fairly straight line across the entire flat surface.

It results due to the sand expansion caused by the heat of the metal, when the sand has insufficient hot
deformation. It also results from poor casting design providing too large a flat surface in the mold cavity.

Buckling is prevented by mixing cereal or wood flour to sand.

DEFECT 3

fissure defect
Possible causes

Metallurgical

• Nitrogen content in the melt too high.

• Titanium content low relative to comparatively high nitrogen content.

• Carbon equivalent low relative to comparatively high nitrogen content.

Resin-bonded sand

• High nitrogen content in the core binder or too much binder

• High formation of gas and poor core venting.

Clay-bonded sand
• High moisture content in the sand and consequently high water absorption by the melt.

• High nitrogen content in the sand resulting from incoming core sand or lustrous carbon producer.

Remedies
Metallurgical

• Reduce proportion of steel in the charge makeup. Reduce nitrogen content to 100 ppm.

• Bind nitrogen content in the melt through the addition of titanium.

• Increase the carbon equivalent.

Resin-bonded sand

• Use binder with lower nitrogen content.

• Use binder with slower release of gas; if possible, use binders with less gas.

• Add iron oxides.

Clay-bonded sand

• Reduce moisture content through better sand development, reduced addition of bentonite and
smaller amounts of inert dust.

• Reduce nitrogen content in the sand. If necessary, reduce lustrous carbon carrier content or use low-
nitrogen carbon carrier.

• If necessary, reduce nitrogen content in the inflowing core sand.

Gating and pouring practice

• Shorten the pouring channels in order to reduce gas pick-up.

• Increase pouring temperature and, if necessary, also the pouring rate

DEFECT 4
Metal Penetration Defects
 Metal penetration is a defect that occurs when the metal enters voids between the sand grains of a
mold. This paper describes the origins and countermeasures of two kinds of metal penetration defects.
In general, an increase in metallostatic pressure makes it easy to cause metal penetration. However,
even if the metallostatic pressure is low, the cast iron penetration occurs. One of the cast iron
penetration is caused by the volumetric expansion during eutectic solidification. When the castings has a
closed loop of isochronal eutectic solidification, the internal pressure rapidly increases with the eutectic
solidification proceeding in this region. If the sand mold is located in the region surrounded by the
closed loop, the metal penetration occurs. The penetration defect of camshaft castings could be
prevented by making sure of the directional solidification toward the riser with proper casting design

Penetration can thus occur as a function of the following

influence factors:
 The grain size of the mold material is too large and the grain particle size distribution is too broad
 The proportions of binder and sediment are too small
 The proportion of materials that form lustrous carbon is too low
 Unfavorable chemical composition of the casting material in combination with casting temperatures
and metallostatic pressure that are too high
 Inadequate and uneven compaction of the molds or cores
 Inadequate gating system and therefore excessive overheating of molds and core components

Insulation in steel and foundry industries

Steel is an iron-carbon alloy that is widely used around the world as a construction material,
in automotive, ships and appliances, as well as surgical tools. It is also recyclable.
According to the World Steel Association, there are 3500 grades of steel. Automobiles
today are built with newer steels that are 35 percent lighter than those used in the past, the
association says. World crude steel production is more than 1.6 billion tonnes annually.
The control of the molten metal temperature in iron and steelmaking processes is of primary
importance to producers, as it affects metal quality, process control and profitability.
At operating temperatures, Pyrotek’s ISOMAG® structural insulation board offers an
optimum balance between excellent insulating properties and high strength that improves
the thermo-mechanical stability of refractory systems in iron and steel-making, as well as
mineral treatment applications. This exhibits lining tightness and resistance to metal
penetration. The forsteritic board reduces thermal shock and skull buildup, increasing
productivity and operating efficiency. It provides excellent strength and dimensional stability
up to 1000°C (1830°F).
ISOMAG board will not only generate energy savings, but also offer new ways to optimize
operation conditions when used in torpedo cars, steel ladles, tundishes or electric arc
furnaces.
 ISOMAG structural insulation provides:

 Reduced temperature loss of molten metal during residence time

 More uniform casting temperature
 Better lining stability
 Higher productivity
 Cost and energy savings
 Improved safety

Foundry Insulation and Safety Basics

 HIGH TEMPERATURE INDUSTRIAL INSULATION
 MICA

Foundry insulation is vital when it comes to foundry safety basics. Foundries work with extreme
heat, using intense temperatures to melt metal and pour it into moulds. Due to the acute and
constant levels of heat that they involve, these processes, therefore, carry a large amount of risk.

Foundries are inherently hazardous places. They will typically reach temperatures over 1425°C.
If, for example, water encounters any active surface at these kind of high temperatures, it
instantly expands to 1,600 times its original volume. Dampness is the enemy in furnaces,
because even slightly damp metal can result in a massive explosion of intensely hot steam, with
potentially catastrophic results.

Foundries require heat without moisture, which also means they create potentially hazardous
conditions for starting fires. Uncontrolled fires are a risk, especially as foundries cannot rely on
using water to put them out, due to the reasons mentioned above.

The solution lies in using flame retardant materials, in ensuring the best possible insulation of
foundries, and in developing and ensuring safe working procedures constantly.

As specialists in foundry insulation and in furnace safety systems, we help and support
the foundry and steel industry to continue to work safely and efficiently.
Mica in Foundry Design
With a basic requirement for thermal insulation and flame retardant materials, foundry design
requires the right materials as a foundation. Rigid mica sheets provide ideal thermal insulation
boards when manufacturing foundries, and apart from its vital application as a foundry lining,
mica is also the basis for various components and process equipment.

Mica has natural mineral qualities of high temperature resistance and low thermal conductivity,
along with high mechanical resistance and versatile machinability. Therefore, it is adaptable
while being highly functional.

Foundry floors must be designed to minimise damage, particularly regarding spillages of molten
metal. Consequently, rigid mica sheet’s non-reactive, flame-retardant qualities make it ideally
suited for this purpose. While safety is always a concern, many foundries now have newer
generations of furnaces that are larger, safer and more efficient.

Foundry Insulation Solutions

The casting process involves charging a furnace with metal, and then heating it above the metal’s
melting point. Charging is a very dangerous operation, requiring care and consistency in
maintaining intense but constant temperatures. Insulation will prevent heat loss, but at the same
time, it is vital that the furnace, and anyone working with, or near, it, is protected.

Mica-based insulation materials support the foundry’s combination of expert processing and
precise thermal management, by extending the lifespan of furnace linings. Mica’s slip pane
characteristics help allow the lining freer movement to expand and contract with a much reduced
likelihood of cracks appearing.

Mica laminates also function to help protect the coil grout and the furnace casting.
There are also benefits in terms of efficiency, with mica foundry insulation increasing relining
speeds and throughput, while reducing the potential for maintenance downtime.

Elmelin’s range of mica laminates and mica roll means we can offer insulation solutions across
the foundry industry, from robust, glass-reinforced mica suitable for larger furnaces, to combi
laminates for furnaces specialising in smelting aluminium and iron.

Early Warning for Coil Damage

Furnaces can be vulnerable to damage and breakdown, with serious implications for a foundry’s
performance. The key is to detect the signs of damage, or a potential threat to the furnace’s
stability, and catch it before it escalates with more serious consequences.

While furnaces which have integral crucibles usually have earth leakage detectors, we can
enhance this by providing an early warning system of potential induction coil damage.

Elmesh is a flexible, mica-based mesh material. It is made from combining a phlogopite mica
layer with another layer of non-magnetic, stainless steel mesh. This material acts as an early
warning when there is a risk of metal penetrating the coil grout – something which can happen
over time, as the crucible starts to wear thin with use. Foundries processing a diverse range of
complex materials, such as scrap metal, are more likely to come across this issue.

This kind of early warning means operators can shut the foundry down before any impairment,
and then take the necessary action to prevent serious damage to the coil happening in future.

This flexible solution comes conveniently packed in rolls, available in various grades of
thickness and roll widths.
Preventing Vapour Deposits
Another foundry safety basic is preventing vapour deposits collecting on the coil. Where
furnaces are processing large quantities of scrap metal that is galvanised, they run the risk of the
material giving off fine oxide dust emissions during melting. Over time, these deposits can
affect the coil’s performance,

causing short-circuits or misreadings.

Zinc oxide can also affect the quality of the smelted metal, with large cavities forming in it as
result of gas build-up.

The Vapourshield mica laminate range works to both protect the coil from these deposits, and
give an early warning where metal is close to penetrating the coil or coil grout during processing.

Vapourshield acts as a temporary barrier, but a timely one: scrap metals with high levels of
impurity can cause the shut-down of furnaces, and mean foundries having the expense of
replacing coils more frequently.

Prevention, Protection and Productivity

Like plenty of other businesses, foundries are looking to reduce their overheads while
maximising their productivity. However, unlike many other businesses, they have inherent risks
and hazards to contend with, in an industry where safety must come first.

Our foundry insulation products address several issues at once: they help prevent damage to
furnaces occurring during essential processes; they act to protect both furnaces and those
working in this environment with thermal barriers and optimised insulation; and they help boost
productivity by making foundry processes more efficient.
Mica-based laminates and microporous insulation solutions are essential to the future
development of the foundry and steel industry, and to its ongoing viability as a dynamic
economic sector.

Foundry Insulation
Proper care and steps taken towards the insulation of pipes, buildings, equipment used
for process produces various advantages. Some of them are contributing towards
maintaining heat needed and thus avoiding heat loss or gain and helps to maintain
temperature consistently, avoid risks for workforce, maintaining comfortable
environment for workforce having hot or cold equipments to work with, and prevent
condensation.

Reasons for Need of Proper Insulation :

The thickness factor determines the insulation factor. That is greater the thickness peak
is the insulation achieved which results in cost cutting. Thus proper management of
insulation for any foundry is very essential.

Also good insulation reduces pollution affecting the environment and helps in
maintaining the surrounding by avoiding gas emissions. Good steps towards proper
insulation also help in efficient energy management.

Most of the energy is obtained by heating fossil fuels if insulation is not done properly
which results in emissions of gas polluting the environment. However, if proper care and
steps are taken for insulation then the loss of heat can be reduced and this contributes
to the role played by fuel for producing heat.
Thus environment is also protected against emissions.

Factors in Insulation :

The advantages of insulation can be achieved by making choice of insulation materials

with study of attributes like halocarbon-free, flammability, resilience, performance and
price.

Insulation could be achieved either by going for thermal insulation or infrared

thermograph depending on the size and usage of foundry.

For instance a small foundry usually goes for thermal insulation taking into account the
initial installation cost of infrared thermograph being high. However larger systems
where usage is long established they prefer to go for infrared thermograph though the
cost is high.

A good consultant in this area called as thermography consultant could provide the best
review and idea to spot and repair items and suggests need for insulation items with
cost effectiveness and efficiency. There is also water-saturated insulation, which helps
to transfer heat much faster than dried process.

However such water-saturated insulation cannot be used for systems, which are using
air-filled voids since those systems must be in dried condition for maximum efficiency.
After proper selection of type of insulation and insulation thickness it is also vital to
make proper steps in cladding of the insulation. In this aspect waterproofing process
plays an integral role.

For applications involving high-temperature proper steps must be taken to let the
moisture out. Insulation with resilient attribute must be used in scenarios where there is
higher possibility of mechanical damage. In these cases insulation with resilient attribute
along with proper steps for protections like shields, jackets, barriers so on must be
made for safety.

Apart from concentrating on thickness of insulation, proper choice of insulation as

needed some other factors like taking proper and consistent steps for reviewing and
correcting repaired insulations, changing damaged or moisture insulations, reducing the
radiation heat loss by avoiding gateways through openings like doors, checking safety
requirements, providing proper insulations as needed to satisfy the same, taking actions
for insulating non-insulated vital items at low cost like pipes must be done for efficient
system maintenance.