CASTING DEFECTS
EXCERPT OF TYPICAL DEFECTS IN CAST IRON
SAND INCLUSION
Description of defect: Hollow spaces are visible
on the casting in isolated cases or over a large
area. Primarily, the defective areas are located
in the upper box or upper part of the casting.
Microscopy: In the micrograph, the cavities
have a smooth wall. In addition, adhesions in
the form of a graphite seam, an oxide layer or,
more rarely, slag residues can be observed.
GAS BLISTER
Description of defect: Hollow spaces are visible
on the casting in isolated cases or over a large
area. Preferably, the defective areas are located
in the upper box or upper part of the casting.
Microscopy: In the micrograph, the cavities
have a smooth wall. In addition, adhesions in
the form of a graphite seam, an oxide layer or,
more rarely, slag residues can be observed.
CAVITIES
Description of defect: Depressions can be
observed on the casting which, depending on
their shape, already have dendritic structures.
Microscopy: In the micrograph, the depressions
can be seen as cavities with a dendritic
structure. The metal could no longer flow
together at these points due to the physical
volume deficit.
*FOSECO and the Logo are trade marks of the Vesuvius Group, registered in certain countries, used under licence. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system of any nature or transmitted in any form or by any means, including photocopying and recording, without the written permission of the copyright holder.
SILICATE SLAG OXIDE SLAG DROSS SLAG
Description of defect: The casting shows a Description of defect: The casting shows an Description of defect: The surface of the
scarred and fissured surface. irregular, partly scarred surface. casting is scarred and fissured.
Microscopy: In the micrograph, silicate slags Microscopy: The micrograph shows oxide slag Microscopy: In the micrograph, choke striae
usually show a dark grey colour and often a in the form of a light grey precipitate. This are characterised by their irregular and linear
highly porous structure. Fine spherical metal shows no reflection under polarised light and structure, which is why they can also be called
residues are often visible in the slag. Under appears dark like the metal. The slag is often slag skins. Chemically, they are usually silicate
polarised light, a glass-like, slightly transparent associated with silicate slags. Chemically, oxide compounds of the elements Mg, Al and other
reflection appears. Chemically, they are usually slags mostly consist of Fe oxides, although Mg accompanying elements of the Mg treatment.
silicate compounds of the elements Mn, Al and oxides (Dross) can also be found in GJV and
Ca. In GJV and GJS, Mg is a main component. GJS.
PINHOLES DISPERSED SHRINKAGE WHITE COATING
Description of defect: Roundish pinprick- Description of defect: Crack-like or regularly Description of defect: The defect is directly
shaped depressions or hollows are visible on shaped cavities can be seen on the casting, visible on the casting as a white coating or often
the outside of the casting or just below the which are aligned perpendicular to the casting only a scarred surface with pits remains after
surface. They can occur sporadically and over a surface in a row, similar to a comma. the blasting process. Under the SEM, a fibrous,
large area. Microscopy: In the micrograph, this defect porous structure of the surface is visible.
Microscopy: In the micrograph, this defect appears equivalent to pinholes and is often Microscopy: In the micrograph, a sintered
pattern appears as a cavity with a predominantly associated with them. The difference, however, residue reaching into the metal is visible. At
smooth wall, usually without a surface coating. lies in the fact that the cavities, in addition to a high magnification, the glassy character of
The cavities appear isolated and clearly smooth wall, are primarily elongated. the residue can be visualised by polarisation.
delineated from each other. Chemically, it is amorphous SiO₂.
GRAPHITE FLOTATION CHUNKY GRAPHITE INOCULANT INCLUSIONS
Description of defect: The casting shows a Description of defect: Dark spots to large-scale Description of defect: The casting shows a
dark shading over a large area, preferably in the shading appear on the casting. scarred, irregular casting surface.
area of the casting surface. The defect is often Microscopy: The micrograph shows locally and Microscopy: In the micrograph, inoculant
accompanied by gas pores. cellularly arranged fine graphite. This structure residues appear similarly bright to the metal, but
Microscopy: The micrograph shows a front of is particularly well visible in the etched state. do not contain graphite. These are not attacked
coarser and densely packed graphite spheres. This Within the cells, the graphite is lamellar and by etching and can thus be differentiated from
graphite is also called primary graphite, which clearly distinguishes itself from the spherulitic the metallic basic structure. Chemically, these
precipitates in hypereutectic cast iron. basic structure. are usually silicon-based additives such as FeSi.