ME 333 Manufacturing Process I

Lecture 09
Casting Defects
Types of Defects Inspection Methods Moulding Related Defects Filling Related Def
ects Solidification Related Defects Defects Analysis
2006 Prof. B. Ravi, Mechanical Engineering Department, Indian Institute of Techn
ology, Bombay.
Types of Defects
Based on Location: External Internal Based on Type: Geometric Integrity Based on
Size/Severity: Small/Minor Large/Major Based on Process: Moulding-related Filli
ng-related Solidification-related. Based on Cause: Raw materials Product design
Tooling design Process parameters Process control Based on Stage: Casting Rough
machining Finish machining Service Based on Reparability: Repairable Irreparable
Inspection Methods
Destructive: Sectioning, Machining Mechanical testing Chemical testing Non-Destr
uctive: Visual: large external defects Dimensional: size defects Pressure testin
g: leakage Radiography: internal holes Ultrasound: internal discontinuities Eddy
current: hardness, structure Magnetic Particle: sub-surface discontinuities Dye
Penetrant: defects with opening to surface.
Moulding-related Defects
Improper Closure Across parting plane: flash Along parting line: mismatch
FLASH
MISMATCH
[Atlas of Casting Defects, Institute of British Foundrymen]
Filling-related Defects
Incomplete Filling: cold shut, misrun. Gaseous Entrapments: blow hole, gas poros
ity. Solid Inclusions: sand inclusion, slag inclusion.
[Atlas of Casting Defects, Institute of British Foundrymen]
COLD SHUT
MISRUN
BLOW HOLE
GAS POROSITY
Solidification/Cooling-related Defects
Solidification Shrinkage: cavity, porosity, centerline, sink. Hindered Cooling C
ontraction: hot tear, crack, distortion.
SHRINKAGE CAVITY
[Atlas of Casting Defects, Institute of British Foundrymen]
POROSITY
SINK
CORNER SHRINKAGE
CRACK
Defects Analysis
Individual Defect: Defect identification Cause identification Remedy specificati
on Defects over a batch/period: Quality control charts Defect frequency (histogr
am) Defect spectrum (pattern over time) Expert Systems for Defects Analysis Know
ledge base (IF-THEN rules with confidence) Inference Engine
Summary
Casting defects are significant: typically 1-10% About 20 major types of casting
defects:
Flash, mismatch, cold shut, misrun, blow hole, gas porosity, shrinkage cavity, p
orosity, centerline, sink, hot tear, crack, scab, swell, metal penetration, roug
h surface. Other defects: improper composition and properties.
Implications:
Minor defects can be repaired, with cost increase. Major defects lead to rejecti
on, with loss of productivity.
Status and Progress:
Quality control and defects analysis: experts/systems. Quality certification and
assurance gaining importance. Responsibility shifting to manufacturer; legal im
plications. Toward zero defects: prevention is better than cure!
Home Exercise
Draw the cause-effect (Ishikawa) diagram for the following defects: Shrinkage po
rosity, Blow hole, Mismatch. Include causes related to moulding, filling and sol
idification. For each of above group of causes, identify the sub-causes (ex. imp
roper filling), and sub-sub-causes (ex. ingate too small). Write the IF-THEN rul
es for identifying and troubleshooting (cause) the following defects: shrinkage
porosity, gas porosity.