RTFI Q&E (CTMS 308196) PARTICIPANT INFORMATION (CASTINGS. Casting is the process of causing molten liquid metal to fill a cavity, normally into a mold which solidifies into a particular shape. Casting discontinuities are similar to welding discontinuities, as a weld is nothing more than a form of a casting. However, radiographic film interpretation of castings is more difficult than interpreting welds due to the complexity of the shapes. Since some castings have areas of wide varying thickness, complete coverage with acceptable film densities and contrast is difficult to obtain. A radiographer can use a film to examine only certain areas where discontinuities are more likely to be found, or he can use two or more different speeds of film in one film holder to represent each area of different thickness. Casting Processes As with welding, the film interpreter needs to be familiar with the type of casting process and the associated discontinuities with each process. By knowing the casting process, he can determine which areas are susceptible to certain types of discontinuities. The most basic of all casting processes is a sand mold casting. A mold or pattern is formed into the shape of the desired product and sand is placed into the mold which is in two halves. The molten metal is then poured into the mold and allowed to solidify. Permanent mold castings are produced in a permanent reusable mold which is made of a high-temperature resistant material. The molten metal is poured into the mold and allowed to solicit Die castings are produced by forcing the molten metal under pressure into a permanent mold and allowed to solidify. Investment castings are produced from a pattern made of wax that is surrounded by a plaster mold made of refractory. The wax pattern is removed by heat leaving the refractory mold to be filled with molten metal which is allowed to solidify. The mold is then broken off from around the casting. a