HOT TOPICS

Issue #9-2003

Casting Defect: Inclusions Sand

1. Defect code G131-CI-GS (Cast iron in green sand)
2. Name: Sand inclusions
3. Description:
Non metallic materials (molding or core sand) present in the casting surface.
Some times these materials are removed from the casting during shot blasting
leaving a void on the surface of the casting. If the graphite shape is not affected
near the defective areas, it is good chance that the defect is caused by sand
inclusions. If the defect is at the bottom most parts of the casting, it is probably
sand.
4. Pictures of this defect are located at the end of this document.
5. Mechanism of defect formation
There are two ways sand defects occur in the casting.
A) Sand already present prior to pouring: Sand that falls into the cavity during
core setting, mold closing, and/or mold handling rests at the lowest levels of the
cavity. When blowing loose sand out of the mold after core setting, loose sand can
be moved around and not expelled from the mold will accumulate at shadow
areas.
b) Sand washed into the casting during pouring. During pouring, sand from
gating systems and cavity areas may be eroded and washes into the casting cavity.
Disturbed mold surface may be washed by flowing metal or may separate from
the rest of the mold and fall into the cavity prior or during mold filling.
6. All possible causes
Design
Very high pouring rates, metal stream impacting the mold
Very long pouring times
Sharp corners on runner systems
Too much metal flowing through one gate
Very long pouring times
Not adequate crush strips on parting banks
Narrow and deep pockets near metal flow areas
Equipment
Pattern equipment worn, negative drafts, not enough draft, fillets loose etc.
Uneven mold stripping, closing and core setting equipment
Al Alagarsamy, Citation Corporation, Birmingham, AL.

 Rough mold handling equipment, shots on rails

Worn pins and bushings resulting in erratic closure
Machines not aligned properly for smooth traveling (Vertically parted
molds)
Uneven mold compaction
Process
Thin sand ridges formed by cracks in the tooling
Rough pouring cups cut by sprue cutters
Mismatched pouring cup and sprue
Not blowing off loose sand after core setting
Worn out core prints and core boxes resulting in too big a core and too
small a print causing crush during core setting
Cores too soft, uncured that can be eroded easily
Dirty area causing loose sand to fall in
Contaminants in molding sand (core lumps etc.)
Hydraulic oil spill resulting in weak mold
Hot sand drying too fast
Sand friability too high
Compactability too low
Too low clay and fines
Sand not mulled well
Green sand having too low dry strength
7. Most probable causes
Sand not blown from cavities
Mold to mold crush
Core to old crush
Sand too dry (hot sand, low compactability)
Too low moisture (low clay and or fines)
Worn out pins and bushing resulting in shifts and crushes
Worn out tooling
8. Process variables that should be controlled to avoid defect
Use metal gating components in tooling
Provide adequate draft for the type of molding equipment
Use adequate crush strips, especially for offset parting planes
Maintain adequate clay, fines and moisture in the greensand system
Maintain adequate western bentonite for good plasticity and dry strength
Keep the sand system clean, free of core lumps and other contaminants
Keep the sand system full (return sand silo should hold at least 2 hours of
sand consumption)
Return sand should be cooled below 1250F, with around 2% moisture
Compactability at the molding machines should as high as the machines
will allow for good mold production.

Al Alagarsamy, Citation Corporation, Birmingham, AL.

Figure 1. at top showing a micrograph of a section through the sand inclusion on

the casting surface.
Figure 2. Molding edges were very friable due to hot sand and low clay.

Al Alagarsamy, Citation Corporation, Birmingham, AL.

Figure 3. Erosion scabs resulting in sand inclusions. Hot sand and poor mulling and low
amount of sand in return sand silo were the main reasons for this defect.

Figure 4. Casting surface with erosion of molding sand where the metal
impinged on the mold cavity. Too low total clay and low compactability
resulted in low moisture sand with low dry strength causing erosion

Al Alagarsamy, Citation Corporation, Birmingham, AL.

Fig-5 Erosion of molding sand at the junction of sprue and runner as well as
on the runner side. Low dry strength of molding sand due to sand mix
containing low western bentonite in the mix contributed to this defect

Figure 6. Sand falling down from parting line crush

Al Alagarsamy, Citation Corporation, Birmingham, AL.