COBALT CHROME 3

ADMISSION: BDT/2020/67443
NAME: JACKLINE KENDI KIJOGI
DATE OF SUBMISSION: 29TH MARCH 2023
CASTING DEFFECTS
Definition: A casting defect is an unwelcome deviation that develops during the metal casting
process. The cast metal defects are caused by a number of different factors or causes. Some of
the defects created may be disregarded or tolerated, while others are unacceptable and must be
removed for the parts to work better.
CLASSIFICATION OF CASTING DEFECT
Metallurgical defects
 Porosity, sinks, inclusion, dross, soldering.
Defects due to heat:
 Hot tears, cold shut, thermal fatigue.
Mechanically induced defects:
 Surface marks, bending, undercuts

TYPES
 Gas Porosity Defects
 Shrinkage Defects
 Mold Material Defects
 Pouring Metal Defects
 Metallurgical Defects
 Casting Shape Defects
Gas Porosity Defects
Cast metal releases gas as it solidifies because it can't contain as much of it as it can when it's
liquid. Molds are permeable in part to enable gas to escape from them. Gas bubbles may become
trapped inside the metal as a result of impermeability, which can be brought on by a number of
variables. These BUBBLES may consist of:
 Pin holes
Pin openings Also called porosities, pinholes are smaller openings in a casting's top surface.
They are typically visible to the naked eye in groups close or at the casting's surface.
 Blowholes
Blowholes are larger holes that can develop inside a cast component. Interior blowholes, which
are invisible to the unaided eye, can be found using x-ray, harmonic, ultrasonic, or magnetic
analysis. Blisters are a subtype of blowholes that are sparsely covered and shallow
 Open holes
Blowholes, which are bigger holes, can develop inside a cast component. Interior blowholes,
which are invisible to the unaided eye, can be found using x-ray, harmonic, ultrasonic, or
magnetic analysis. Blisters are a subtype of blowholes that are sparsely covered and shallow.
Causes of gas porosity
 Speed of metal pouring is too slow
 Presence of gas in metal.
 Mold is too hot.
 Presence of moisture in flux.
 Incomplete casting.
 Metal section is too thin.
 Overheated molds.
 Temperature of pouring metal is low.
REMEDIES
 Metal is poured as quickly and without interaction as feasible.
 Vacuum degassing is used. Metal should be vacuum-melted.
 Maintain a moderate temperature for the mold.
 Use sufficient core and mold ventilation.
 Have enough metal in the ladel to completely cover the mold.
 Make the gating mechanism better.
 Improve the runner design and change the casting design to prevent the thin metal
section.
 The temperature at which metal is poured should be raised.
SHRINKAGE DEFECTS
Metal alloys contract as they cool, which causes shrinkage defects to show up. An alloy
component will typically shrink as it solidifies. (which should be included in calculations when
designing the mold). Defects, on the other hand, happen when the metal shrinks unevenly,
leading to the creation of interior holes or distortion of the final product's form. This may put
tension on the metal. Below is a list of shrinkage defects:
 Open shrinkage defects: A hole or a dip (also known as a caved surface) caused by open
shrinkage can be seen on the surface of a cast object. (also known as a pipe). These kinds
of flaws occur when metal contracts unevenly, which draws air into the affected region of
the mold.
 Closed shrinkage defects: In a casting, closed shrinkage typically manifests as holes
where a section of the liquid metal was hotter than the remainder of the component. Both
macro and Nano versions are possible. Micro shrinkage, also known as shrinkage
porosity, appears as jagged scars or lines to the unaided eye. Only under a microscope
can one see the angular-looking openings.
 Warping: Warping can alter the dimensions and form of the casting during or after the
metal has solidified. Particularly in the big, flat portions of castings, this stresses the
metal and results in curving.
CAUSES
increased metal concentration in a particular area.
geometric complexity of casting.
Metal is under too little pressure.
Runner and gate construction are poor.
Metal has been contaminated.
Metal capacity decreases during solidification
REMEDIES
 Use extra metal while pouring to avoid the sinks.
 Increase the gate seal time.
 Increase the injection speed to decrease viscosity and allow more backing pressure.
  Relocate gates to problem areas.
 Increase the cooling time of metal.
 Lower the temperature of metal.

MOLD MATERILA DEFECTS

Defects in the mold material can result from problems with the mold structure as well as defects
in the mold material itself. This is the largest category of casting flaws, with seven main types.
When a portion of the mold is eroded away by flowing liquid metal and the sand is insufficiently
heat-resistant to halt it, cuts and washes happen. Cuts and washes show as low bulges along the
finished product's surface that are angled toward the end where the molten metal poured in more
forcefully.
 Swells: Swells show as a swollen area on the finished piece. When the mold is too
flexible, the sand is pushed outward by the weight of the molten metal, which results in
these flaws.
 Drops: On the tops of molds, drops appear as erratic bumps. When the mold is fragile,
sand can tumble into the liquid metal and cause them. Additionally, drops muddy up the
metal's surface.
 Runout: This is when the mold leaks, leaving insufficient metal to create the intended
casting.
CAUSES
As mentioned, the defect produced can have a variety of causes. However, the majority of flaws
are either brought on by too-soft molds that require additional ramming or by pouring in metal
while it is still too hot.
REMEDIES
All of these issues can be reduced by making sure the molds receive sufficient ramming to hold
the molten metal and that the metal being poured isn't too hot. If that doesn't work, there are
alternative fixes available that differ for each flaw. Changes to gate systems or the addition of
more binders to the sand may be necessary for cuts and washes. Swells can be prevented by
reducing the amount of water in the sand in the mold.
POURING METAL DEFECTS
These flaws, as opposed to many of the others in this manual, are caused by pouring at temps
that are too low. They can be divided into three groups:
 Cold Shot: Leftover from molten metal splatters as it was being poured, cold shot
consists of balls or drops that are loosely connected to the casting. The splatters become
embedded or attached because they cool more quickly than the remainder of the casting
because they are smaller.
 Cold shut: When metal enters a mold from two or more points, but is too cold to combine
into a single component, this is known as a "cold shut." At that point, it causes a middle
crack with rounded edges, which turns into a weak area in the casting.
CAUSES
Simple metal pouring at an insufficient temperature can result in these flaws. Even though the
metal was initially poured at the ideal temperature, defects may still result from inadequate
gating systems that let the metal cool off too much before it enters the mold or from thin cast
sections. Thin sections can solidify and block off other mold sections due to their thin size.
REMEDIES
For the most part, pouring metal flaws can be avoided by making sure the molten metal stays
warm enough to perfectly conform to the inside of the mold. The gating system can be altered to
move the molten metal more quickly or to avoid areas where it will solidify before filling larger
cavities beyond them. If that’s not feasible, the pouring temperature can simply be increased.
Increasing the mold’s gas permeability can also make the gases evacuate faster, so that the metal
has less time to cool while still flowing into the mold. Cold shot specifically can be caused by
careless pouring, so ensuring the metal is poured smoothly can also help with this problem.
METALLURGIC DEFECTS
When a casting's metal has issues, there are metallurgical flaws that become visible. There are
three different kinds, including:
 Slag Inclusion: When metal isn't thoroughly cleansed of slag before being poured, slag
inclusion occurs. It simply means that there will be impurities or foreign material
embedded in the final casting. The appearance of the molds will be spongy or
honeycomb-like if the inclusion is dirt.
 Hot Tears: Also referred to as hot fissures, hot tears appear when cooling metal contracts.
When the metal is in this condition and still brittle, residual tension or a bad mold design
 can cause the metal to pull apart, leading to branching, irregular cracks. These can
occasionally be challenging to see with the unaided vision.
CAUSES
i) The presence of slag in the molten metal
ii) Improper mold design.
Remedies
(i) Remove slag particles form the molten metal before pouring it into the mold cavity.
(ii) Proper mold design can easily eliminate these types of casting defects.
(iii) Elimination of residual stress from the material of the casting.

CASTING SHAPE DEFECTS

Mismatches or flare are two ways that casting defects manifest themselves. Shape flaws are
among the simplest to correct because they typically call for modifying pre-existing models.
 Mismatches: Also known as shifts, mismatches occur when various casting components
emerge out of alignment with one another, typically laterally. Similar to how misaligned
cores result in vertical movement, misaligned cores also cause core shift.
 Flash: Flash—also known as casting fins or burrs—appear as extra material adhered to
the casting, typically in the form of a thin sheet that develops where sections of a mold
meet. One of the most prevalent casting flaws is flash.
CAUSES
 incorrect top and lower part alignment during mold preparation.
 Misalignment of flask (a flask is type of tool which is used to contain a mold in metal
casting. Any practical form, such as a square, circle, rectangle, or other, may be used.)
REMEDIES
 Proper alignment of the pattern or die part, molding boxes.
 Correct mountings of pattern on pattern plates.
 Check the alignment of flask.