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Defects, Causes and Their Remedies in Casting Process PDF
Defects, Causes and Their Remedies in Casting Process PDF
3, March 2014
E-ISSN: 2321-9637
Shegaon1 2
Email: rajeshrajkolhe@Gmail.com1 , itsjaweed@yahoo.com2
Abstract- Foundry industries in developing countries suffer from poor quality and productivity due to involvement
of number of process parameter. Even in completely controlled process, defect in casting are observed and hence
casting process is also known as process of uncertainty which challenges explanation about the cause of casting
defects. In order to identify the casting defect and problem related to casting, the study is aimed in the research
work. This will be beneficial in enhancing the yield of casting. Beside this, standardization (optimization) of process
parameter for entire cycle of manufacturing of the critical part is intended in the proposed work. This study aims to
finding different defects in casting, analysis of defect and providing their remedies with their causes. In this paper
an attempt has been made to list different types of casting defects and their root causes of occurrence. This paper
also aims to provide correct guideline to quality control department to find casting defects and will help them to
analyze defects which are not desired.
Keywords: Casting; defects in casting; quality control in casting; causes and remedies for casting defects.
1. INTRODUCTION
Casting is a process which carries risk of failure 2. CASTING DEFECT CAN BE CLASSIFIED AS
occurrence during all the process of accomplishment of FOLLOWS-
the finished product. Hence necessary action should be
taken while manufacturing of cast product so that defect 2.1. Filling related defect
free parts are obtained. Mostly casting defects are
concerned with process parameters. Hence one has to 2.2. Shape related defect
control the process parameter to achieve zero defect
parts. For controlling process parameter one must have 2.3. Thermal defect
knowledge about effect of process parameter on casting
and their influence on defect. 2.4. Defect by appearance
To obtain this all knowledge about casting defect,
their causes, and defect remedies one has to be analyze These defects are explained as follows.
casting defects. Casting defect analysis is the process of
finding root causes of occurrence of defects in the 2.1 Filling related defects
rejection of casting and taking necessary step to reduce
the defects and to improve the casting yield. 2.1.1. Blowhole:-
In this review paper an attempt has been made to Blowhole is a kind of cavities defect, which is also
provide all casting related defect with their causes and divided into pinhole and subsurface blowhole. Pinhole
remedies. is very tiny hole. Subsurface blowhole only can be seen
During the process of casting, there is always a after machining. Gases entrapped by solidifying metal
chance where defect will occur. Minor defect can be on the surface of the casting, which results in a rounded
adjusted easily but high rejected rates could lead to or oval blowhole as a cavity. Frequently associated with
significant change at high cost. Therefore it is essential slag’s or oxides. The defects are nearly always located
for die caster to have knowledge on the type of defect in the cope part of the mould in poorly vented pockets
and undercuts.
and be able to identify the exact root cause, and their
remedies.
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International Journal of Research in Advent Technology, Vol.2, No.3, March 2014
E-ISSN: 2321-9637
Thin sand crusts firmly adhering to the casting. The
defect occurs to a greater extent in the case of thick-
walled castings and at high temperatures.
The high temperature to which the sand is subjected
causes sintering of the bentonite and silicate
components. In addition, the always present iron oxides
combine with the low-melting-point silicates to form
Fig.1 Blowhole
2.1.1.1. Possible causes iron silicates, thereby further reducing the sinter point of
Resin-bonded sand the sand. Sintering and melting of the impurities in the
• Inadequate core venting moulding sand enable the molten iron to penetrate even
• Excessive release of gas from core faster, these layers then frequently and firmly adhering
• Excessive moisture absorption by the cores to the casting surface.
• Low gas permeability of the core sand
Clay-bonded sand
• Moisture content of sand too high, or water
released too quickly
• Gas permeability of the sand too low
• Sand temperature too high
• Bentonite content too high
• Too much gas released from lustrous carbon
producer
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International Journal of Research in Advent Technology, Vol.2, No.3, March 2014
E-ISSN: 2321-9637
• Reduce liquid metal temperature • Pouring rate too high, with heavy impact against
mould wall surface resulting in erosion
2.1.3. Sand inclusion • Ladle too far above pouring basin
Sand inclusion and slag inclusion are also called as • Pouring time too long
scab or blacking scab. They are inclusion defects. Looks
like there are slag inside of metal castings. 2.1.3.2. Remedies
Irregularly formed sand inclusions, close to the Moulding plant
casting surface, combined with metallic protuberances • Check moulds for pressure marks and, if
at other points. Sand inclusion is one of the most necessary, insert pressure pads
frequent causes of casting rejection. It is often difficult • Carefully blow out mould cavities
to diagnose, as these defects generally occur at widely • Improve pattern plates, increase pattern tapers and
varying positions and are therefore very difficult to radii. Heat pattern plates and, if necessary, use
attribute to a local cause. Areas of sand are often torn release agent.
away by the metal stream and then float to the surface • Check the moulding plant for uniform flask
of the casting because they cannot be wetted by the stripping and overhaul moulding plant as necessary
molten metal. Sand inclusions frequently appear in • Automate core-setting. Check and, if necessary,
association with CO blowholes and slag particles. Sand modify core prints before start of production
inclusions can also be trapped under the casting surface • Ensure uniform mould compaction, avoid over-
in combination with metal oxides and slag’s, and only compacted sections
become visible during machining. If a loose section of
sand is washed away from one part of the mould, Clay-bonded sand
metallic protuberances will occur here and have to be • Raise compactability and thus plasticity of the
removed. sand
• Increase bentonite content. Use bentonite with
high specific binding capacity. Improve bentonite
development by ex-tending mixing time or by pre-
wetting used sand
• Reduce inert dust content. Decreasing the dust
content re-duces lumps in the sand.
• Reduce content of lustrous carbon producer
Resin-bonded sand
Fig.3 Sand inclusion • Increase the strength of the cores. Use greater
proportion of binder.
2.1.3.1. Possible causes • Compact cores more evenly and effectively and, if
Moulding plant necessary, inject gas more evenly
• Break-up of mould sections during stripping of • Avoid core mismatching.
patterns, core setting or assembling of moulding
flasks Gating and pouring practice
• Uneven compaction of moulds, compaction too • Avoid high pouring rates and impact of metal
high in places. stream against mould walls
• Shorten pouring times, improve distribution of
Clay-bonded sand gates.
• Low compactability
• Bentonite content too low, or poorly developed 2.1.4. Cold lap or cold shut
bentonite Cold lap or also called as cold shut. It is a crack with
• Inert material content too high round edges. Cold lap is because of low melting
• Lump content too high temperature or poor gating system.
• High content of lustrous carbon producer When the metal is unable to fill the mould cavity
completely and thus leaving unfilled portion called
Resin-bonded sand misrun. A cold shunt is called when two metal streams
• Low core strength do not fuse together properly.
• Excessive core mismatching
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International Journal of Research in Advent Technology, Vol.2, No.3, March 2014
E-ISSN: 2321-9637
Air is present in the cavity before the shot. It can
easily be trapped as the metal starts to fill the cavity.
The air is then compressed as more and more metal
streams into the cavity and the pressure rises. When the
cavity is full it becomes dispersed as small spheres of
high pressure air. The swirling flow can cause them to
become elongated.
.
Fig. 4 cold shut
2.1.4.1. Possible Causes
• Lack of fluidity in molten metal
Fig. 6 Gas porosity
• Faulty design
2.1.6.1. Possible Causes
• Faulty gating
• Metal pouring temperature too low.
• Insufficient metal fluidity e.g. carbon
2.1.4.2. Remedies:
equivalent too low.
• Adjust proper pouring temperature
• Pouring too slow.
• Modify design
• Slag on the metal surface.
• Modify gating system
• Interruption to pouring during filling of the
mould.
2.1.5. Misrun
Misrun defect is a kind of incomplete casting defect, • High gas pressure in the mould arising from
which causes the casting uncompleted. The edge of molding material having high moisture and/or
defect is round and smooth. volatile content and/or low permeability.
When the metal is unable to fill the mould cavity • Lustrous carbon from the molding process.
completely and thus leaving unfilled portion called • Metal section too thin.
misrun. A cold shunt is called when two metal streams • Inadequately pre-heated metallic moulds.
do not fuse together properly.
2.1.6.2. Remedies
• Increase metal pouring temperature.
• Modify metal composition to improve fluidity.
• Pour metal as rapidly as possible without
interruption. Improve mould filling by modification
to running and gating system.
• Remove slag from metal surface.
• Reduce gas pressure in the mould by
Fig.5 Misrun appropriate adjustment to moulding material
properties and ensuring
2.1.5.1. Possible Causes • Adequate venting of moulds and cores.
• Lack of fluidity in molten metal • Eliminate lustrous carbon where applicable.
• Faulty design • If possible, modify casting design to avoid thin
• Faulty gating sections.
• Ensure metal moulds are adequately pre-heated
2.1.5.2. Remedies and use insulating coatings.
• Adjust proper pouring temperature
• Modify design 2.2. Shape defects
• Modify gating system 2.2.1. Mismatch defect
Mismatch in mold defect is because of the shifting
2.1.6. Gas porosity molding flashes. It will cause the dislocation at the
The gas can be from trapped air, hydrogen dissolved parting line.
in aluminum alloys, moisture from water based die
lubricants or steam from cracked cooling lines.
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E-ISSN: 2321-9637
There are a number of different causes of flash and
the amount and severity can vary from a minor
inconvenience to a major quality issue.
At the very least, flash is waste material, which
mainly turns into dross when re-melted, and therefore
is a hidden cost to the business.
Fig. 7 Mismatch
2.2.3.2. Remedies
Fig. 8 Distortion If your sprue is very tall and the casting covers a
wide area of the mold face, it's very possible for the
2.2.2.1. Possible causes mold to actually be forced up by the hydrostatic
Distortion due to warp age can occur over time in a pressure of the metal. The seriousness of this depends
casting that partially or completely liberates residual density of the metal (aluminum is very light, but be
stresses. careful with a bronze pour!) and the weight of the mold
fighting it. The solution here is very simple: weight
2.2.2.2. Remedies down the mold.
Common practice in iron casting is normalizing heat
treatment to remove residual stress. In aluminum 2.3. Thermal defects
2.3.1. Cracks or tears
casting, a straightening between quench and aging
Cracks can appear in die castings from a number
might be required. of causes. Some cracks are very obvious and can
easily be seen with the naked eye. Other cracks are
2.2.3. Flash defect very difficult to see without magnification.
Flash can be described as any unwanted, excess
metal which comes out of the die attached to the
cavity or runner.
Typically it forms a thin sheet of metal at the
parting faces.
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E-ISSN: 2321-9637
Fig. 10 Crack
Fig. 11 Shrinkage
2.3.1.1. Possible causes
• Shrinkage of the casting within the die 2.3.2.1. Possible causes
• Undercuts or damage in die cavities The density of a die casting alloy in the molten state
• Uneven, or excessive, ejection forces is less than its density in the solid state. Therefore, when
• Thermal imbalance in the die an alloy changes phase from the molten state to the solid
state, it always shrinks in size.
• Insufficient draft in sections of the die
This shrinkage takes place when the casting is
• Excessive porosity in critical regions of the
solidifying inside a die casting die. At the centre of
part
thick sections of a casting, this shrinkage can end up as
• Product design not matched to the process many small voids known as ‘shrinkage porosity’.
• Inadequate die design If the shrinkage porosity is small in diameter and
confined to the very centre of thick sections it will
2.3.1.2. Remedies usually cause no problems.
• Reduce dry strength, add saw dust/ coal dust However, if it is larger in size, or joined together, it
• Reduce pouring temperature can severely weaken a casting. It is also a particular
• Avoid superheating of metal problem for castings which need to be gas tight or water
• Use chills tight’.
• Provide feeders
• Avoid early knockout. Give sufficient cooling 2.3.2.2. Remedies
time. The general technique for eliminating shrinkage
• Correct composition porosity is to ensure that liquid metal under pressure
• Reduce sharp corners continues to flow into the voids as they form.
2.3.2. Shrinkage 2.3. 3. Sink mark
Shrinkage defects occur when feed metal is not Solving molding sink mark and void problems
available to compensate for shrinkage as the metal Definition: Sink marks and voids both result from
solidifies. Shrinkage defects can be split into two localized shrinkage of the material at thick sections
different types: open shrinkage defects and closed without sufficient compensation.
shrinkage defects. Open shrinkage defects are open to Sink marks appear as depressions on the surface of a
the atmosphere, therefore as the shrinkage cavity forms molded part. These depressions are typically very small;
air compensates. There are two types of open air however they are often quite visible, because they
defects: pipes and caved surfaces. Pipes form at the reflect light in different directions to the part. The
surface of the casting and burrow into the casting, while visibility of sink marks is a function of the color of the
caved surfaces are shallow cavities that form across the part as well as its surface texture so depth is only one
surface of the casting. criterion. Although sink marks do not affect part
Closed shrinkage defects, also known as shrinkage strength or function, they are perceived to be severe
porosity, are defects that form within the casting. quality defects.
Isolated pools of liquid form inside solidified metal, Voids are holes enclosed inside a part. These can be a
which are called hot spots. The shrinkage defect usually single hole or a group of smaller holes. Voids are
forms at the top of the hot spots. They require a caused when the outer skin of the part is stiff enough to
nucleation point, so impurities and dissolved gas can resist the shrinkage forces thus preventing a surface
induce closed shrinkage defects. The defects are broken depression. Instead, the material core will shrink,
up into macroporosity and microporosity (or creating voids inside the part. Voids may have severe
microshrinkage), where macroporosity can be seen by impact on the structural performance of the part.
the naked eye and microporosity cannot. molding sink mark and void.
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College of Technology, Coimbatore, India.
1raguramsingh1990@gmail.com *Assistant
Professor, Department of Mechanical Engineering,
PSG College of Technology, Coimbatore, India.
2syathpsgtech@gmail.com
[6]. Process optimization as a tool in the analysis of
steel casting defects By Dr.Hathibelagal Roshan,
Chief Metallurgist Maynard Steel Casting
Fig. 19 Rat tail Company Milwaukee, WI 53217
[7]. Silver anniversary paper,div5 Porosity defects in
2.4.7.1. POSSIBLE CAUSES iron casting from mold metal interface reaction.
• A rat tail is caused by depression of a part of R.l.naro.aci international,inc,cleveland,ohio.
the mould under compression which appears as an [8]. Modeling of shrinkage defects during solidification
irregular line on the surface of the casting. of long and short freezing materials A. Reisa,∗, Y.
• A buckle is a more severe failure of the sand Houbaertc, Zhian Xub, Rob Van Tol b, A.D.
surface under compression. Santosa, J.F. Duartea, A.B. Magalha˜ esa a FEUP –
Faculdade de Engenharia da Universidade do Porto,
2.4.7.2. REMEDIES Porto, Portugal b WTCM Foundry Center,
The mould must provide for proper expansion Research Center of Belgium Metalworking
instead of forming compressed layers to avoid this Industry, 9052 Zwijnaarde, Gent, Belgium c UGent
defect. – University of Ghent, Technologiepark Zwijnaarde
903, Gent, Belgium
3. CONCLUSION
In this research work different casting defects are
studied. By referring different research papers causes
and their remedies are listed. These will help to quality
control department of casting industries for analysis of
casting defect. This study will definitely be helpful in
improving the productivity and yield of the casting.
Rejections of the casting on the basis of the casting
defect should be as minimized and all the above
research is heading in the same direction.
REFERANCES
[1]. “Review of Casting Defect Analysis to Initiate the
Improvement Process”A.P.More, Dr.R.N.Baxi,
Dr.S.B.Jaju Mechanical Engineering Department,
G.H.Raisoni College of Engineering, Nagpur.
440016 (India)
[2].Defect formation in cast iron Lennart Elmquist
School of Engineering Jönköping University,
Sweden Tammerfors, Finland, November 8, 2012
[3]. Analysis of Casting Defects and Identification of
Remedial Measures – A Diagnostic Study Dr D.N.
Shivappa1, Mr Rohit2, Mr. Abhijit Bhattacharya3
International Journal of Engineering Inventions ISSN:
2278-7461, www.ijeijournal.com Volume 1, Issue 6
(October2012) PP: 01-05
[4]Casting Defect Analysis using Design of
Experiments (DoE) and Computer Aided Casting
Simulation Technique Uday A. Dabade* and Rahul
C. Bhedasgaonkar,(2013)
[5]. Reduction of defects in grey cast iron castings by
six sigma approach Raguramsingh.M#1, Syath
Abuthakeer.S*2 #ME Lean Manufacturing, PSG
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