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Castingdefects 150609030024 Lva1 App6892 PDF
Castingdefects 150609030024 Lva1 App6892 PDF
Typical characteristics:
Sand washout, combined with sand and /or
slag inclusions because of low strength or
molten metal flowing at high speed
Preferred defect locations:
Mostly close to the gate or on edges, which
tend to heat
Cuts and Washes
Remedial measures:
Choose binder with good properties at high
temperatures
Greater compaction of the mould sand
Avoid high flow speeds and long pouring times
Improve gate design to reduce turbulence and by
increasing size of the gates
Metal Penetration
More or less thick sand adhesions on the
casting, which are held fast on the work piece
by metal penetrations. The metal between the
grains cannot always be identified by the
naked eye.
Widespread, frequently cushion-shaped form.
Can often not be removed by blasting.
Penetrating adhesions in blackened moulds
and cores can often be cracked off the work
piece using a chisel
Typical characteristics:
Metal between sand grains. Can often only be
identified with a microscope.
Remedial measures:
- Higher binder content
- More uniform compaction
- Reduce casting /sprue height
Washout/Erosion
Manifestation:
Thickening of the casting at one place.
Typical characteristics:
Sand washout, combined with sand and /or slag
inclusions.
Preferred defect locations:
Mostly close to the gate or on edges, which tend to
heat up
Remedial measures:
- Choose binder with good properties at high
temperatures
- Greater compaction of the mould sand
- Avoid high flow speeds and long pouring times
Pouring Metal Defects
Mis Runs and Cold shuts
Metal unable to fill the mold cavity completely
Cold shut is caused when two metal streams
while meeting in the mold cavity do not fuse
together properly, thus causing a discontinuity
or weak spot.
Remedial measures:
- Increase casting temperature
- Increase casting speed and make gates
larger
Cold shot inclusion/ spray
bead
Spray beads are pearl or bead shaped inclusions,
which are only loosely bonded with the metal. They
are partly already visible at the surface, they are
often not exposed until the machining.
Remedial measures:
- Reduce elements which bond with oxygen
- Properly dry ladles beforehand
- Reduce pouring times
- Increase mixing time
Hot Tears
Material partition in liquid /solid state, which occurred
as the stresses, which occurred in the casting in the
area of the elastic deformations, were larger than the
strength of the material.
Stresses can occur in case of uneven cooling
conditions (differences in wall thicknesses). Special
design of the casting can prevent contraction. –
shrinkage onto the core -
Hot cracks primarily occur in steel castings.
preferred defect locations:
- at sudden, steep transitions in wall thicknesses.
- at wall thickness transitions with too small radii
Remedial measures:
- Design suitable for stresses, balance out cross-
sections with large wall thicknesses
Core damage
Unintentional protruding(extension) core parts.
Typical characteristics:
Parts of the core are displaced relative to each other.
Preferred defect locations:
At parting lines of the cores.
Remedial measures:
Visual
Imperf ection on
Machined
Surf ace (52%)
Casting Failed
Pressurized
Leak Test
(28%)
Defects Causing Surface Imperfection (relative
frequency of each defect found)
Lubricant or
Mold Coating
Inclusions on
Surface (16%)
Oxide
Inclusions Gas Porosity
(38%) (85%)
Cold Laps
(46%)
Flow Lines
Shrinkage
(7.7%)
Porosity (69%)
Defects Causing Pressurized
Leak Test Failure
(relative frequency of each defect found)
Mechanical
Cracks (14.3%)
Cold Laps
(57.1%)
Gas Porosity
(57.1%)
Shrinkage
Porosity
(71.4%)
Defects Causing Casting Breakage at Machining
(relative frequency of each defect found)
Mechanical
Cracks (25%)
Gas Porosity
Oxide Inclusions (75%)
(25%)
Cold Laps
(75%)
Shrinkage
Porosity (75%)