Defect Type Major Cuse Practically observed sub Causes

Insufficient Venting ,excessive Moisture

in moulding the sand,low permability
and excessive fine grain sand, excessive
Mould Making
moisture absorption by the core, cores
neither properly baked nor adequatly
vented

sharp corner of pattern (Gas may

Blowhole Cating accumulate of mould cavity), presense
Defect of gas producing ingredients in the
Pattern
mold or core sands, Manual work of
fitments of gating system, match palte
arrangements of pattern

Riser and Gating system Improper Gating System design, which

Design causes turbulence and aspiration of air

Too low or high pouring temparature

Melting furnace and improper pouring melt no sufficiently
pouring Process degasifies, inadequate of melting
temparature
 Possible Remedies

use molding sand have the

following required properties Dry
sand moulding fineness number
between 45-65 for cast iron, clay
content ≤ 2 %, permability 100-
150 , use venting at sharp corner,
use of metal pattern

Avoid sharp corner during pattern

making correct pattern design
procedure, use of aluminium
pattern to improve surface finish
and free from moisture , fixed
position of matmate and gating
arangements

proper design of gating system

use temparature measuring

instrument such as pyrometer
adjust pouring time, keep puring
temparature 1418 to 1432°C help to
reduce the defects
 Major Cuse Practically observed sub Causes

High Pouring temparature can induced

High Pouring Temaparature
impurities (Slag/sand) In metal

High pouring rate can cut the edge in

High Pouring Rate
penetrate the metal surface

uneven ramming can penetrate metal

low compatibility
surface to sand or slag
 Possible Remedies

Maintain pouring Temparature (1418° to

1432°c) in range

maintain uniform pouring rate

always maintain even ramming

 Major Cuse Practically observed sub Causes Possible Remedies

Insufficient Venting ,excessive

use molding sand have the following
Moisture in moulding the sand,low required properties Dry sand
permability and excessive fine
Inadequate Mould moulding fineness number between
Making grain sand, excessive moisture 45-65 for cast iron, clay content ≤ 2 %,
absorption by the core, cores
permability 100-150 , use venting at
neither properly baked nor
sharp corner, use of metal pattern
adequatly vented
sharp corner of pattern (Gas may
Avoid sharp corner during pattern
accumulate of mould cavity),
making correct pattern design
presense of gas producing
ingredients in the mold or core procedure, use of aluminium pattern
Pattern
to improve surface finish and free
sands, Manual work of fitments of
from moisture , fixed position of
gating system, match palte
matmate and gating arangements
arrangements of pattern
Improper Gating System design,
Riser and Gating
which causes turbulence and proper design of gating system
system Design
aspiration of air
Too low or high pouring use temparature measuring
temparature improper pouring instrument such as pyrometer adjust
Melting furnace and
melt no sufficiently degasifies, pouring time, keep puring
pouring Process
inadequate of melting temparature 1418 to 1432°C help to
temparature reduce the defects
uneven ramming can penetrate
low compatibility always maintain even ramming
metal surface to sand or slag

impurities causes disturbances in

Mesh should be use to trap the
Material Impurities metal flow and metal start
solidification during mouring impurities