MIS-RUN CASTINGS

Definition of Mis-run Castings

 A casting is regarded as mis-run if it is incomplete

owing to an interruption to metal flow before the
mould cavity filled. So, a casting is regarded as mis-
run if a piece is missing, or corners that should be
sharp are rounded, or there is lack of definition. Fig. 1. Mis-run light section
casting
 The interruption to metal flow occurs because some
of the metal becomes solid before the mould is full
or because debris clogs the system. A cold shut is
regarded as a mis-run.
 Mis-running is mainly a hazard in the production of
thinner section castings but it is not entirely
confined to them. Fig. 2. Cold lap in light
section casting
 Fig. 1 shows a light section engineering casting
which has mis-run to the extent that a sizeable piece
of the casting is missing, while Fig. 2 shows a
casting of similar thickness containing a cold lap or
‘seam’ which is also a type of mis-running.
 By comparison Fig. 3 shows a wide cold lap in the
side wall of a large engine casting weighing over Fig. 3. Cold lap in side wall
one ton. This lap occurred because the metal was of large engine casting
allowed to cool to too low a temperature before
pouring the casting.
 Mis-run and Cold Shuts

 When the liquid metal enters the mould, the
first requirement is that it should
satisfactorily fill the mould cavity and
develop a smooth skin through intimate
contact with the mould surface.
 Cold shuts are more serious, the
discontinuity extending completely through
a casting member in which streams of metal
have converged from different directions.

 Gross failure to meet these conditions

produces the most serious defect in this
group, the misrun or short run casting, in
which the metal solidifies prematurely and
some limb or section of the casting is
omitted.

 Cold laps are a less severe manifestation of

the same fault. These arise when the metal
fails to flow freely over the mould surface;
the intermittent flow pattern is retained on
solidification due to lack of coalescence of
liquid stream.

Cold laps and shut in a steel casting

 The first sign of conditions giving rise to such defects is the occurrence of rounded
corners and edges and a general lack of definition of sharp features and fine mould detail.

 The defects are most generally associated with metal temperature, cold metal being the
usual cause in castings for which the production method is normally satisfactory.

 A further cause can be excessive chill from the mould face; this may arise from heavy
chilling or from too high a moisture content in greensand.

 Laps may be encountered, for example, when a method developed for dry-sand practice is
used in conjunction with greensand instead.
 A contributing cause to these defects can be an inadequate rate of mould filling relative to
the freezing rate of the casting: especially susceptible, therefore, are extended castings of
high surface area to volume ratio.

 Slow mould filling may result from low pouring speed, from an inadequate gating system,
or as a result of back pressure of gases in a badly vented mould cavity, several aspects of
the casting method are therefore involved in prevention.

 Alloys showing poor fluidity, especially those carrying strong oxide films, are particularly
prone to defects resulting from improper flow. In these cases special techniques of gating
and high superheat are the principal aids to sharp outlines and completely filled moulds.
 Causes of Mis-running

 Mis-running depends on the fluidity of the iron in relation to the design of the casting being filled.
The important factors are shown diagrammatically in Fig. 4 and are:
1. The fluidity of the molten iron
2. The design of castings and running-systems
3. The mould, and mould-production techniques
4. Pouring technique

Fig. 4. Causes of mis-running

 Fluidity of the iron  Highly alloyed irons may have different
fluidity properties in certain cases, e.g.
high aluminium or chromium irons form
 The fluidity or running qualities of the iron are influenced solely a skin on the metal surface which can be
by pouring-temperature – which is the most important factor – detrimental to metal flow.
and chemical composition.
 In all but highly alloyed irons, the influence of composition
depends upon carbon, silicon and phosphorus contents only. The
formula

establishes the relative effects of these elements, and all irons of

the same CEF value at the same pouring-temperature have the
same fluidity properties. Fig. 5 illustrates the effect of CEF value
and pouring-temperature on fluidity.

 The improvement of fluidity at a given pouring-temperature,

brought about by increasing the CEF value, occurs because the
solidification temperature is correspondingly low.

 Any change of composition which reduces the solidification

temperature will thus improve fluidity, and this applies to all
irons whether they solidify white or grey or in the SG form. Fig. 5. The effect of CEF value and pouring-
temperature on fluidity
 There is a limit to the improvement of
fluidity with increasing CEF value, which
occurs at a carbon equivalent of about 4.7.
At this stage, kish graphite precipitated
from the melt becomes a serious problem
and can markedly decrease fluidity as
shown in Fig. 6.
 To some extent, very high sulphur irons can
have inferior fluidity due to the formation
of excessive quantities of manganese
sulphide which also can clog running
systems.
 However, should the irons contain so much
sulphur or so much kish graphite that their
quantities become detrimental to fluidity, it Fig. 6. Fluidity decreased by kish graphite.
is probable that the castings would be
unsatisfactory for other metallurgical
reasons even if they were not mis=run.
 Design of castings and running-systems

 In castings of the same weight the ‘chunky’ castings with relatively thick sections are
less likely to be mis-run than the thin-section intricate castings. Providing the running-
systems are sufficiently well designed to prevent ladle slags and dross from being drawn
into the castings, they should allow the fastest possible filling of the mould.

 There should be minimum constriction in the running-system, and short thick sprues are
preferable to long thin sprues.

 It is a mistake to think that increasing the height of the sprue will increase the power of
the metal to fill a casting, because of the higher ferrostatic pressure.

Pouring technique

 Slow or interrupted pouring can give rise to mis-run castings. Pouring should be
continuous and as rapid as possible.
 Mould production

 A mis-run may occur if a mould builds up a gas pressure

because the permeability of the sand is low. Such mis-
runs can be prevented by appropriate venting. Care
should be taken to clean loose sand from patterns and
moulds, otherwise – as with slag, manganese sulphide
or kish – any constrictions in the castings may become
clogged.

 Even within the dimensional tolerances of castings some

castings will be thinner than others made to the same
design or from the same pattern. Obviously, if mis-
running is a problem the thinner castings will be more
susceptible than the thicker ones – even within the
dimensional tolerances. Sometimes the thinner and
thicker sections are not apparent in castings if a core is
mis-placed. An example of a mis-run (mainly a cold
shut) caused by a mis-placed core in a burner casting is
illustrated in Fig. 7. Fig. 7. A mis-run, caused by a misplaced
core, in a burner casting
 How to Avoid Mis-run Castings

 If occasional mis-run occur in many types of castings made in a foundry the most likely
causes are faulty moulds or pouring-techniques. Attention should therefore be given to
proper training for, and supervision of:

 maintenance;

 cleaning of loose sand from patterns and moulds;

 skimming;

 the actual casting process.

 If one or two types of the castings are particularly susceptible to mis-runs, attention
should be given to their design and to the designs of the numbers, gates and vents.
 How to Avoid Mis-run Castings (Cont’d.)

 If a foundry experiences alternative trouble-free and troublesome periods, it is most likely

that the fluidity of the metal is at fault; in particular, metal temperature will probably be low.

 Appropriate furnace and ladle control is required.

 Ladles should be preheated before use, and drum ladles or covered ladles are
recommended to avoid unnecessary heat-loss during transportation of metal.

 Changing the chemical composition of the iron is not recommended – an increase of

temperature of 20C will improve fluidity more than raising the carbon equivalent by
0.1 percent.

 If poor fluidity is due to a change of composition it would appear that technical

control was poor and the grade of iron would be altered rendering some castings
unsatisfactory for reasons other than mis-running.

 The best universal action to prevent mis-runs is to keep the metal temperature high and
adequately supervise all moulding and casting operations.
Examples of Incomplete Casting and
Discontinuity Defects
Misruns

A portion of the casting is missing, usually on the cope surface or at a location remote from the gate
area. The edges surrounding the missing portion are rounded. Adjacent surfaces are generally shiny.

The gates, runners and sprue are well-filled.

Possible Causes

 Inadequate pouring temperature; insufficient metal fluidity, oxidized metal.

 Gates too small or improperly located with respect to the shape and thickness of the casting
 In permanent moulding, low mold temperature or inadequate venting

Remedies

 Raise pouring temperature

 Modify size and arrangement of gating system
 Provide more effective venting system
 Raise mold temperature (permanent molding)
 If possible, arrange with customer to increase section thickness somewhat
Cast Iron, Green Sand Cast Iron Green Sand

Connection box cover of gray cast iron. Pour at Gray iron pillow block lining. Areas near the
higher temperature defect are shinny. Pour at higher temperature
Copper Alloy, Permanent Mold Aluminum Alloy, Permanent Mold

Permanent molded brass valve body, 120 mm Aluminum permanent mold casting 60 mm (2.4
(4.8 in.) high. Casting is incomplete. A misrun in.) in diameter (handwheel) showing misrun.
occurred but sections remote from the gate Shorten the cycle between pourings in order to
show no evidence of pouring too cold. maintain adequate mold temperature.

During pouring, the top flange of the casting

filled with liquid metal prior to the walls. The
entrapped air could not escape, causing a
misrun. The defect was eliminated by enlarging
the sprues.
Casting is complete except for projecting edges which are more or less rounded. In the case
of cast iron, the surface is generally shiny and is quite easily cleaned.

Possible Causes

 Lack of fluidity (castability) of the liquid metal

due to a pouring temperature too low for the alloy
composition in question.
 Slow filling of the mold cavity because of gates which are too small.
 Inadequate venting (permeability, vents, relief risers)
 In permanent molding low mold temperature

Remedies

 Maintain adequate pouring temperature with regard to composition and section size.
 Check gate areas and increase where possible.
 In permanent molding, raise mold temperature
 Increase permeability and venting of mold
Cast Iron, Green Sand Cast Iron, Permanent Mold

Alloy gray iron pillow block cover. Corners are Gray iron permanent mold casting
not filled due to low pouring temperature, note
shiny surface % C/3.80 Si/2.50 Mn/0.90 S/0.10 P/0.30

Casting at left pouring between 1420 and 1450C;

casting is good. The one on the right, poured at
1350C did not fill completely.
Copper Alloy, Permanent Mold

Cupro-aluminum casting (slightly less than

actual size). Increase venting to permit
escape of air at blade location.
Poured Short

The upper portion of the casting is missing. The edge adjacent to the missing section are slightly
rounded; all other contours conform to the pattern. The sprue, risers and lateral vents are filled only to
the same height above the parting line as is the casting (contrary to what is observed in the cast of
defect).

Possible Causes

 Insufficient quantity of liquid metal in the ladle

 Premature interruption of pouring due to workman’s
error (assumption mold is filled due to rapid filling and
overflow of choked sprue).

Remedies

 Have sufficient metal in the ladle to fill the mold

 Check the gating system
 Instruct pouring crew and supervise pouring practice
Cast Iron, Green Sand

Gray iron castings with attached riser

and runner system

Above: Good
Below: Castings have been poured
short due to insufficient metal
remaining in the ladle (castings
and riser at same level)
Cold Shut or Cold Lap

A linear discontinuity with rounded edges.

The defect has a characteristic appearance
and may vary in depth, extending either
partially or entirely through the section of
the casting. In the mildest case, it may
consist merely of a shallow groove with
rounded edges. This defect may be
accompanied by the presence of rounded
edges and corners on the casting itself.

Cold shut occurs on wide surfaces of the

casting, in thin sections which are difficult
to fill, or where two streams of metal
converge in the mold because of sequence
of filling.
 Possible Causes

 Insufficient fluidity, oxidized metal

 Slow or interrupted pouring
 Insufficient venting
 In diecasting: incomplete fusion of two streams of metal (the two often showing different
structures due to differences in cooling rates).

Remedies

 Pour at higher temperatures

 Increase the fluidity of the alloy
 Increase mold filling rate by changes in gating
 Improve venting of the mold.

For metallic molds:

 Adjust mold and metal temperatures (increase, usually).

 Heat the mold wall selectively or improve temperature control of the mold at the defect
location
 Refine the gating system
 Check the mold wash in terms of insulating qualities.
Cast Iron, Green Sand

Cast iron housing showing cold shut.

Ductile Iron, Green Sand

Ductile iron support bracket, unit weight

1.35 kg (2.97 lb).

The spherical portion of the casting in the

left foreground shows a pronounced cold
shut.

Principal cause: Reduction in filling rate

due to sprue being cut through off-center
(visible at right).

Remedy: Provide enlargement base

below sprue to eliminate chances of
sprue misalignment. Use venting above
the sphere to eliminate back-pressure of
mold gases during filling.
Aluminum Alloy, Die Cast

Aluminum alloy die casting with cold shut Photomicrograph of casting shown.
partially covered by chrome plating
Aluminum Alloy, Die Cast Aluminum Alloy, Die Cast

Light metal diecasting showing a cold shut. Demonstrating the difference in

microstructures between rapidly-cooled metal
and that of the surrounding metal which cooled
more slowly (Al-Si-Cu alloy diecasting).
Aluminum Alloy, Die Cast Aluminum Alloy, Die Cast

Light alloy diecasting containing a cold shut Light alloy diecasting containing a cold shut.
Steel, Cement Molding Cast Iron, Green Sand

Ni-Cr-Mo steel casting made in a Fragment of a bathtub casting showing cold

cement mold with an oil-sand core; shut. The casting was bottom-gated;
weight about 3.5 kg (7.7 lb). Cold shut insufficient filling velocity and restricted
resulted from pouring too cold escape of gases from the mold.

First trial castings showed open blows.

Increased metal pressure eliminated the
blows but failed to achieve complete fusion.
Runout

A portion of the casting is missing. The cope surface is usually concave and the sidewalls
may extend upwards as fins which more or less follow the edges of the mold.

The missing portion, especially in the case of thick parts, may be localized within the
interior of the casting, which appears to have been drained.

Do not confuse with misrun and poured short.

 Possible Causes

 Poorly-sealed mold or insufficient strength of mold walls or cores (esp. for thick
castings); the walls break under high metallostatic pressure.
 Negligence in sealing holes used for mold or core assembly
 Poorly-sealed core vents.
 Surfaces of cope and drag pattern plates do not match (warped). In hand molding –
poorly-sealed mold joint; in machine molding – warped plates
 Insufficient mold weights or clamping force
 Premature shakeout (casting not solidified).

In the case of an improperly weighted or clamped mold, this defect occurs in

NOTE
conjunction with raised mold.

Remedy

Correct the possible causes listed above.

Cast Iron, Green Sand
Pillow block cover of gray cast iron. The mold
cavity partially drained after being completely
filled. Cleanup or weight the flasks adequately.
Cast Iron, Dry Sand
Gray iron casting. After complete filling of the
mold cavity, a large internal core filled with
coke developed a crack and allowed a
portion of the iron to drain slowly into the
center of the core.
Aluminum Alloy, Permanent Mold Malleable Iron, Green Sand

Permanent molded aluminum alloy piston, Differential housing of malleable iron. Metal
runout occurred due to premature opening of has partially drained away after filling of the
the mold mold due to mold rupture at the parting line
adjacent to the runners.
Interrupted Pour

A seam which appears as a visible joint along a horizontal plane of the casting. The two
portions of the casting may be entirely separated or fused together only in certain areas.
The lower portion has rounded edges.

Possible Causes

 Irregularities in pouring which lead to

momentary interruption of metal flow while the
mold is filling.
 Insufficiency of metal in the ladle, the
momentary delay before filling from another
ladle permits the surface of the first metal to
begin to solidify.

Remedies

 Avoid any irregularities in pouring

 Be sure there is sufficient metal in the ladle to fill the mold
 Check the ladle dimensions (normal volume).
Cast Iron, Green Sand

Interrupted pour. Volume of the pouring ladle was insufficient to fill the mold cavity;
the missing metal was added from a second ladle, but too late to avoid the start of
solidification of the first iron. Fusion did not occur and the casting is in two pieces.