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The defects are broken up into macroporosity and microporosity (or microshrinkage), where macroporosity can be
seen by the naked eye and microporosity cannot.[4][5]
Terminology
The terms defect and discontinuity refer to two specic and separate things in castings. Defects are dened
as conditions in a casting that must be corrected or removed, or the casting must be rejected. Discontinuities,
also known as imperfections, are dened as interruptions in the physical continuity of the casting. Therefore, if the casting is less than perfect, but still useful
and in tolerance, the imperfections should be deemed
discontinuities.[2]
Types
2.1
Shrinkage defects
Closed shrinkage defects, also known as shrinkage porosity, are defects that form within the casting. Isolated pools
of liquid form inside solidied metal, which are called hot
spots. The shrinkage defect usually forms at the top of the
hot spots. They require a nucleation point, so impurities
and dissolved gas can induce closed shrinkage defects.
1
Tiny gas bubbles are called porosities, but larger gas bubbles are called a blowholes[13] or blisters. Such defects can
be caused by air entrained in the melt, steam or smoke
from the casting sand, or other gasses from the melt or
mold. (Vacuum holes caused by metal shrinkage (see
above) may also be loosely referred to as 'blowholes).
Proper foundry practices, including melt preparation and
mold design, can reduce the occurrence of these defects.
Because they are often surrounded by a skin of sound
metal, blowholes may be dicult to detect, requiring harmonic, ultrasonic, magnetic, or X-ray (i.e., industrial CT
scanning) analysis.
3.1
Die casting
3.2
Continuous casting
3.3
Sand casting
4 See also
Sand casting has many defects that can occur due to the
mold failing. The mold usually fails because of one of
two reasons: the wrong material is used or it is improperly
rammed.[22]
Porosity sealing
5 References
[1] Rao 1999, p. 195
[2] ASM International (2008). Casting Design and Performance. ASM International. p. 34. ISBN 978-0-87170724-6.
[3] Rao 1999, p. 198
[4] Stefanescu 2008, p. 69
[5] Yu 2002, p. 305
[6] Degarmo, Black & Kohser 2003, pp. 283284
[7] Campbell 2003, p. 277
[8] Gas Porosity in Aluminum Casting, Compiled AFS Literature, March 2002
[9] Campbell 2003, p. 197
[10] Sias, Fred R (2005). Lost-wax Casting: Old, New, and
[13] Roxburgh, William (1919). General Foundry Practice. Constable & Company. pp. 3032. ISBN
9781409719717.
5.1
Bibliography
REFERENCES
6.1
Text
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Images
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6.3
Content license