Professional Documents
Culture Documents
1. Definition
Casting defect 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. 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.
2. Types
There are six main types of casting defects:
1. Gas Porosity Defects
2. Shrinkage Defects
3. Mold Material Defects
4. Pouring Metal Defects
5. Metallurgical Defects
6. Casting Shape Defects
➢ Blow Holes: Blowholes are larger holes that can appear in the inside of a cast piece. Invisible
to the naked eye, interior blowholes are detectable by x-ray, harmonic, ultrasonic, or magnetic
analysis. Blisters, a variant of blowholes, are thinly covered shallow holes.
4. Shrinkage Defects
Shrinkage defects appear because metal alloys shrink as they cool. It is normal for an alloy piece to
shrink as it solidifies (which should be included in calculations when designing the mold). However,
defects occur when the metal shrinks unevenly, causing it to either distort the shape of the final product
or create interior holes. This can also stress the metal. Shrinkage defects are given below:
➢ Open Shrinkage Defects: Open shrinkage shows up on the surface of a cast product either as
a dip (also known as a caved surface) or a hole (also known as a pipe). When metal shrinks
unevenly, it draws air inside the mold in that area to create these types of defects.
➢ Warping: Warping can happen either during the metal’s solidification or afterward, changing
the casting’s dimensions and shape. This stresses the metal and causes curving, especially in
large and flat sections of castings.
Figure3. 6: Warping
➢ Swells: Swells show up as a swollen area on the finished piece. These defects happen when
the mold is too soft, so that the weight of the liquid metal pushes the sand outward.
➢ Drops: Drops show up as irregular bumps on the tops of castings. They’re caused when the
mold is weak and sand falls into the liquid metal. Drops also make the metal surface dirty.
Figure3. 9: Drops
➢ Runout: Runout happens when the mold leaks, leaving an inadequate amount of metal to form
the desired casting.
➢ Fusion: Fusion shows up as a glassy looking crust on the surface of a cast piece. It happens
when some of the sand in the mold melts and fuses with the casting.
➢ Metal Penetration: When sand grains are both loose and large, molten metal can penetrate
into the mold, creating a rough surface in the casting.
➢ Rat Tails: Rat tails, also known as veins, are irregular lines along a casting’s surface caused
when the heat of the molten metal makes the sand expand. Buckles are more extreme versions
of rat tails.
➢ Cold Shut: Cold shuts occur when metal flows into a mold from two or more points, but it’s
too cold to merge into a seamless piece. That’s when it creates a crack through the middle with
rounded edges, which becomes a weak spot in the casting.
8. Metallurgical Defects
Metallurgical defects show up when there are problems in the metal of a casting. There are three types,
which include:
➢ Slag Inclusion: Slag inclusion happens when metal isn’t properly cleared of slag before being
poured. It simply means the finished casting will have impurities or foreign material embedded
in it. When the inclusion is dirt, castings will have a honeycomb or spongy look.
➢ Hot Tears: Hot tears, also known as hot cracks, show up when the cooling metal contracts. In
this state, when the metal is still weak, residual stress in the metal or poor mold design can
cause the metal to pull apart, resulting in branching, irregular cracks. Sometimes these are
difficult to see with the naked eye.
Figure3. 18: Hot Tears Defect
➢ Hot Spots: Also known as hard spots, these defects occur when certain parts of a casting cool
off faster than the areas around them, creating harder parts of the casting. These can wear out
tools and interfere in the machining process.
➢ Flash: Also called casting fins or burrs, flash shows up as extra material attached to the casting,
usually as a thin sheet that forms where parts of a mold meet. Flash is one of the most common
casting defects.