Casting defects

It is an unwanted irregularity that appear in the casting during metal casting process. There is
various reason or sources which is responsible for the defects in the cast metal. Here in this section,
we will discuss all the major types of casting defects. Some of the defects produced may be
neglected or tolerated and some are not acceptable, it must be eliminated for better functioning of
the parts.

Casting Effects and Their Remedies

Types of defects and cause Remedies Pictures

➢ Gas porosity • Pouring of metal is done as
Gas porosity in casting is due to rapidly as possible without
presence of gas which is in the interaction.
form of trapped air, moisture from • Use vacuum degassing. Melt
water-based die lubricant, the metal in vacuum.
dissolved hydrogen in air. When • Keep the temperature of
the pouring of metal starts the air mold low.
which is present in the cavity • Use adequate venting of
before pouring is compressed and molds and cores
the pressure rises. It forms the
bubbles after it has cooled.
Cause:
• Speed of metal pouring is too
slow
• Presence of gas in metal.
• Mold is too hot.

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 ➢ Sinks •Use extra metal while
Sinks form when there is presence pouring to avoid the sinks.
of sub-surface cavity. A sink is • Increase the gate seal time.
depression impacting of surface of • Increase the injection speed
part that does not mimic the mold to decrease viscosity and
surface. Sinks are often visible allow more backing pressure.
because they reflect light. • Relocate gates to problem
Cause: areas.
• Insufficient metal can be main • Increase the cooling time of
reason for sinks. metal.
• Gate seal time is slow.
• Low injection speed.
• High volumetric shrinkage.
➢ Soldering • Give more time for cooling.
Soldering is one of the main and • Maintenance of die surface.
major casting defects in aluminum • Lower the temperature of
die casting process. Soldering die.
occurs when molten aluminum • Use proper lubricant.
sticks the surface of die steel and
remain there after the ejection of
casting. Soldering occurs after just
few castings cycle.
Cause:
• Poor gate design.
• Inadequate die cooling.
• Poor die surface polishing.
• High temperature of die.

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 ➢ Segregation • Segregation can be removed
Segregation occurs due change in by homogenization heat
chemical composition of metal. treatment.
Segregation is distinguished
between two types. Micro
segregation and Macro
segregation. Micro segregation
refers to localize difference
between dendrite arm. Distance
involved is about 10 to 100µm
which is small for diffusion to be
significant mechanism and this is
not in case of microdegeneration.

Cause:
• Local and non-equilibrium
composition can lead to
Segregation.
➢ Cracks • Proper design of casting.
Cracks are usually irregular and • Use chillers in casting areas
oxides so that fracture appears • Give proper time for cooling
dark. Crack is geometrical of metal.
discontinuity in casting. Generally, • Reduce proper pouring
crack occurs when casting is still temperature.
hot and contracting. Cracks can be
• Provide feeders
easily seen with the naked eye and
other cracks are difficult to see
without magnification.
Cause:
• More stress localization at
particular area.

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• High thermal concentration.
• Excessive injection forces.
• Damaged die cavities.
• Insufficient draft in die section.
➢ HOT TEARS • Provide adequate fillet at
Hot tears are one of the main junctions.
casting defects. It is due to • There should be uniform
formation of irreversible failures thickness throughout the
of semisolid casting. Hot tears section.
occur in last stage of solidification. • Placement of gate should be
accurate near the die.
Cause: • Use accurate metal pouring
• Thermal contraction. temperature.
• Abrupt section changes in • Use standard solidification
casting. method.
• Improper placement of gates.
• Incorrect metal pouring
temperature.

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