S&B Industrial Minerals GmbH

Burn on
Nature of Defect Thin sand crusts firmly adhering to the casting. Defect occursmore frequently with thickwalled castings at high castingtemperature. Remedies Increase amount of lustrous carbon producers and coke producers in the moulding sand. Increase amount of new sand if sintering point of the sand is low and oolitization is high.

Broken Mould
Nature of Defect Flash-like metal penetration in the mould, sometimes parts of the mould are included in the casting. Remedies Add more bentonite to increase green tensile strength. Raise compactability of the moulding sand.

Erosion
Nature of Defect The sand is washed away, mostly near to the sprue, often accompanied by sand inclusions. Bulges arise on the casting near to the gate. Remedies Avoid drying out of the moulding sand. Increase amount of bentonite in the sand. Increase milling time of the moulding sand. Increase mould compaction. Use carbonaceous additive with a high lustrous carbon producing ability.

Explosion Penetration
Nature of Defect Extensive penetration, when the mould is filled too quickly. Remedies Reduce amount of free water. Increase milling time of the moulding sand. Increase oolitization rate of the moulding sand.

Lustrous Carbon Inclusions

Nature of Defect Formation of surface irregularities, inclusions and laps due to non-wetting characteristic of lustrous carbon, often associated with the use of Cold-Box cores. Remedies Use dried Cold-Box cores. Reduce amount of lustrous carbon producer in the moulding sand. Use carbonaceous additive with a higher coking residue.

Fissure Defect
Nature of Defect Narrow, crack-like cavities vertical to the surface. Dendrite formation in the cavities. Remedies The defect is of a metallurgical nature due to too much nitrogen contained in the iron. Reduce the amount of nitrogen in the moulding sand. Use low nitrogen containing carbonaceous additive. Reduce addition of carbonaceous additive in the moulding sand.

Moulding Sand

Micro Shrinkage
Nature of defect Porous structure found in the area of the casting which is last to solidify. Remedies Defect occurs with alloys having a wide solidification range. Little influencing by the moulding sand. Reduction of organic material and an increase in the moisture level will improve thermal conductivity of the moulding sand.

Scarred Surface
Nature of Defect Scarred casting surface around hot spots, particularly with SG cast iron. Remedies Reduce amount of impurities present in the sand that are destroying the oxide skin.

Blow Holes
Nature of Defect Cavities with smooth walls, singularly or in groups. Remedies Low casting temperatures are often the cause. Benefits may be obtained by increasing mould permeability. Reduce fines or add coarser new sand. Reduce organic additions to the sand.

Penetration
Nature of Defect Roughness caused by the molten metal penetrating the immediate sand grains of the mould surface, particularly in softly rammed areas. Remedies Use finer sand. Improve ramming of the moulds. Reduce compactability of the moulding sand. Increase amount of carbonaceous additive. Increase amount of coke in the moulding sand.

Pin Holes
Nature of Defect Accumulation of small subsurface rounded holes. Defects appear after annealing and light machining. Remedies Normally the defect is of a metallurgical nature. The mould material may have a certain effect. In case of pin holes the moisture, the organic additions and the amount of nitrogen in the moulding sand should be reduced.

Roughness
Nature of Defect Rough casting surface finish due to coarse sand. Remedies Use finer sand. Increase amount of lustrous carbon producing material in the moulding sand. Increase the amount of fines e.g. coke in the sand.

Sand inclusions
Nature of Defect Irregularly formed sand inclusions just underneath the casting surface, associated with products from the metal slag reaction in other areas. Remedies Keep the moulding sand sufficiently plastic by good sand preparation and sand cooling. Adjust to optimum compactability. Reduce the tendency of the mould to stick to the pattern by the use of parting agents.

Slag inclusions
Nature of Defect Non-metallic irregular shaped inclusions, when occurring, tend to be on upper casting surfaces. Remedies The defects are caused by slag being present with the molten metal in the pouring ladle. If the formation is due to eroded sand, reduce the amount of inert fines and use a more active lustrous carbon producer. Increase milling time of the moulding sand.

Scabs
Nature of Defect Mushroom type defect with sharp edges parallel to the casting surface. Remedies Increase bentonite level. Use carbonaceous additive with a wide softening range. Increase the amount of carbonaceous additive in the moulding sand.

Swells
Nature of Defect Irregular bulges, in most cases widely spread, sometimes with rough surface and/or penetration. Remedies Reduce compactability of the moulding sand. Ram moulds better and more evenly. Make sand less sensitive to over- and underramming by increasing the amount of bentonite.

Metal Penetration
Nature of Defect Firmly adhering agglomerates of sand/metal at hot spots and in softly rammed areas. Remedies Reduce compactability of the sand. Improve ramming of the moulds. Increase amount of carbonaceous additive and coke in the moulding sand.

Blow Holes at Angles

Nature of Defect Smooth wall cavities at the angles of the casting. Remedies The cause is insufficient feeding and rate of solidification. Influencing by moulding sand is possible. Reduce the moisture content and the organic additions of the sand. Improve the venting of the mould.