CASTING DEFECTS AND CAUSES

Sl.No. Defect Causes

Loose Ramming of moulds
Friability
Sand Inclusion
Loose sand around chills & Sleeves

1 Vents not properly cleaned

Improper placement of vents
Vents not placed according to the method card
Vents not opened in mould
Mould improperly heated after coating
Gas Holes Excess moisture in sand
Core gas not removed
Oil,rusty,painted scrap used for melting
Holding liquid metal in the furnace for a long time
2 Melting practice shall be according to the procedure
Collapsible agent not sufficient/added in sand
Mould too hard
Core too hard
High pouring temperature

Mould disturbed after pouring

Crack Early knockout of moulds
Heavy risering in moulds
Heavy chills in moulds
Too short soaking temperature in Heat Treatment
Improper quenching
Quench to tempering gap more
3 Welding of defects
Parting line leak in moulds
Improper closing of moulds
Interrupted Pouring
Clamping not done in the moulds
4 Unskilled pouring personnel
 CASTING DEFECTS AND CAUSES

Too low pouring temperature

Insufficient Sprue size
Cold Shut Metal transfer distance & time more
laddle not properly preheated
5 Improper gating ratio
Poor risering & chill design in moulds
Improper placement of risers & chills
Wrong size riser placed in moulds
Shrinkage

Excess pouring above the riser

6 Improper methoding
 CASTING DEFECTS AND CAUSES

Countermeasure
Ramming shall be tight
Gas passing shallbe according to the norms
Correct size chills to be used.
Sand to be cleaned around the Sleeves
To clean the vents properly through air

Place the vents as per method card

All vents need to be opened before coating
Heat the moulds according to the procedure
Moisture level needs to be checked before mixing
Provision shall be made in corebox
Charge should be cleaned before melting
Tap the metal once ready.If holding neans reduce the temp.
Sequence shall be as per the procedure
Add the collapsible agent as per procedure

Add binding oil as per the procedure

Pouring temperature shall be maintained optimum i.e. per procedure

Moulds shall not be disturbed immediately after pouring.Sufficient time shall

be given
Risering shall be as per method card
Chills shall be as per method card
Soaking temp. shall be as per the section thickness
Quenching heat treatment shall be proper.Q.C. to witness
Tempering shall be done within 4 hours
Welding shall be as per the approved WPS
Parting line shall be pasted with thin clay
Moulds shall be opened & closed to ensure seating
All the moulds need to be clamped tightly
Skilled persons shall be employed for pouring
 CASTING DEFECTS AND CAUSES

Pouring temperature shall be maintained optimum i.e. per procedure

Sprue design shall be simulated
Mould to be lined nearer to the furnace
laddle shall be prehested to minimum C
Design shall be robust with simulation
Design shall be robust with simulation

Risers & Chills shall be as per method card

Pouring shall be stopped once risers ae filled.No excess pouring shall be done
Design shall be robust with simulation