International Journal on Theoretical and Applied Research in Mechanical Engineering (IJTARME)

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Sand moulded castings Defects, Causes, Remedies – Review Paper

Landage M. G.
Mechanical Engineering Department, Indira College of Engineering & Management, Pune.
Email: milind.landage@indiraicem.ac.in

correct identification of defects and its root causes and

Abstract – Casting process is one of the important
manufacturing process and it involves no. of steps
involving methoding, tooling manufacturing, moulding,
melting and pouring, fettling, shot blasting to produce sand
moulded casting. As process involves number of steps, no.
of variables affect the quality of casting.In order to
produce good quality casting it is esssential to avoid defects
in casting which can controll the rejection of
casting.Rejection of casting leads to problems like loss of
economy as well as loss of credit of casting
manufacturer.This paper involve review of the study of
variety of casting defects, their root causes and remedies.
Key words – Casting; defects in casting Defect Analysis,
Defect Prevention, Root Cause Analysis
I. INTRODUCTION
Casting manufacturing is one of the manufacturing
process having application in pumps,valves,machine
tools,i.c.engine components,special purpose
machine,hydraulic and pneumatic
components,compressors,electical components etc. This
clearly indicates versatality of applications. vitioning are
primary requirements in many industrial applications.
As application scope varies from component to
component it becomes more critical to understand the
process thoroughly.When thease cast components are
used in assembly then again it require to understand
customer requirements to get more clarity about
fullfilling uninterrupted supply of casting to the
customer,oherwise delays in supply may hold the
assembly line work.Uninterrupted supply of quality
castings to customer is always challenge.Quality casting
mahufacturing is dependent on number of factors
basically related with process sequence ,its
standardization for product variety,assurance of the
process control,historic data management,record
generation and its preservation, smart inspection
techniques, use of correct standards i.e.as per customer
requirement, effective interdepartmental
communication and customer communication and
casting rejection analysis involving reduction in
rejection percemtage. .
II. LITERATURE REVIEW
Harshwardhan Pandit in paper , “ WebCADAS: A New
Online Education System for Casting Defect
Identification, Analysis and Optimisation of Parameters
”, discuss about using new system WebCADAS for 2)Study of Feasibility - it involves study by maufacturer
casting defect analysis.The system uses Elearning for material of casting ,Grade of casting , specification
study ,quantity requirement by customer , time span
technology which involves variety of images to facilitate
required to process the quantity with avilable resources ,
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remedies.[1]
P. Sathish Kumar , A. Ramesh , and M. Gokul in paper,
“ Present Approches For Analysis Of Casting Defects :
A Review ” ,discuss about different approaches use
presently for casting defect analysis[2]
Avinash Juriani in paper , “ Casting Defects Analysis in
Foundry and Their Remedial Measures with Industrial
Case Studies ” , discuss regarding critical casting
defects ,root causes and remedies for casting defect
controll [3]
Dr D.N. Shivappa , Mr Rohit , Mr. Abhijit Bhattacharya
,in paper “Analysis of Casting Defects and Identification
of Remedial Measures- A Diagnostic Study ” , discuss
about work carried out at Dakshin Foundry Ltd.
Banglore India The study involve defects –sand drop
,blow holes ,mismatch ,over size of component Trunion
Support Bracket [4]
A.P.More ,,Dr.R.N.Baxi,,Dr.S.B.Jaju in paper, “ Review
of Casting Defect Analysis to Initiate the Improvement
Process ” , discuss about improvement in the process of
critical casting manufacturing to enhance quality and
reduce cost of casting component[5]
Rajesh Rajkolhe , J. G. Khan in paper , “ Defects,
Causes and Their Remedies in Casting Process: A
Review ,discuss about defect identification ” ,defect
variety ,root causes ,remedies and also casting yield
improvement and process standardization.[6]
Beeresh chatrad , Nithin Kammar, Prasanna P Kulkarni,
Srinivas patil in paper , “ A Study on Minimization of
Critical Defects in Casting Process Considering Various
Parameters ”, discuss the importance of correct
identification of casting defects ,root causes and
remedies of grey cast iron cylinder liner so that re-
occurences of defect could be eliminated due to it.[7]
III. METHODOLOGY
Casting Manufacturing involves –
1) Receipt of Customer drawing – it should be
preferably Casting Drawing , if Machining Drawing is
provided then it needs to be converted to Casting
Drawing , aliong with Standard followed by customer
for approval by customer
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approximate weight of casting
3)Costing of Casting – it involve consideration of direct
cost , indirect cost along with profit margin
accountability
4)Customer feedback for acceptance of offer sent by
casting manufacturer
This is initial activity requirqed to be completed by
Casting Manufacturer.After this casting development is
initiated.
Casting Development involves :
A)Methoding – Involve finalisation of Lay-out work(
parting line selection for pattern ,core boxes required
i.e.number of cores in component , different allownces
finalisation ) ,preparation of Method Card( mentions
details about mouldig , pouring , inspection , fettling),
mfg.of tooling ( pattern & core boxes), approval for
issue of tooling to moulding section ( witnessing
inspection report )
B)Moulding – it involves manufacturing of
moulds,cores and final mould assembly
C)Melting and pouring – it involves preparing required
grade of molten metal and pouring molten metal into
mould
D)Casting Cooling – it involves keeping poured mould
for cooling purpose
E)Fettling – it involves removal of unwanted part like
gating system , and shot blasting.
F) Inspection – it involve dimensional inspection and
laboratory inspection , customer clearance
G) Despatch to Customer – it involve transfer of
physical casting to customer.
The above steps are carried out for any new casting
manufactured by the casting manufacturer.The
manufactured casting may be rejected due to number of
reasons.If casting is rejected by customer , then
whatever efforts taken by casting manufacture are
wasted.It is loss of the company as amount invested for
this activity becomes waste.There is loss of credit in
market as customer is not satisfied .
When we think about rejection , the word Defect comes
in front of us.
Defect Detection :
TABLE I : CASTING DEFECTS, ROOT CAUSES AND REMEDIES.
Defect Root cause
Blow holes 1. Excessive moisture content in molding 1. Control of moisture content.
sand.
2. Rust and moisture on chills
3. Cores not sufficiently baked.
4. Excessive use of organic binders.
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i) Diagnosis
ii) Remedy
Diagnosis involves first identifying the symptoms,
second defining the defect and decide possible root
causes.
Remedy involves analysis of possible root causes,taking
corrective actions and again manufacture new
casting.The result of new maufactured casting is ensured
for defectfreeness.
Defect is nothing but variation of casting from
specification.It may be co-related with variation in
process i.e.poor process control.The problems can be
listed as:
1)Methoding Problems
2)Tooling Problems
3)Moulding Problems
4)Melting and Pouring Problems
5)Casting cooling Problems
6)Fettling Problems
7)Inspection Problems
As we list above possibilities, we can identify poblem
and possible source of origin of problem.Methoding
problems involve variations related to weight of casting ,
gating system issues ,lay out issues, specification
issues.Moulding problems involves issues regarding
mould and core production.Melting and pouring
problems involve issues regarding metal preparation and
pouring practice issues.Casting cooling problems
involve issue regarding time requirment.Fettling
problems involve issue regarding wrong metal
removal.Inspection problem involve issues regarding
incorrect drawing reading ,incorrect calculation of
dimension and accrdingly improper inspection of tooling
as well as casting.After desppatch , problem of damages
of casting related to improper handling by transporter,
happen in any of the components.For defect detction ,
analysis and remedies , brain storming activity involving
representatives from methoding,moulding,melting and
pouring,fettling and inspection can proove more
effective technique.It can lead to exchange of ideas
while tackling case to case rejection problems.Defect
study is important as defect reduces output and increases
cost of production affecting economy. Different types of
defects, root cause and remedies :
Remedy
2. Use of rust free chills, chaplet
and clean inserts.
3. Bake cores properly.
4. Ram the mold less hard.
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5. Molds not adequately vented.

6. Molds not adequately vented.
Shrinkage 1. Faulty gating and risering system. 1. Ensure proper directional
2. Improper chilling.. solidification by modifying
gating, risering and chilling.
Porosity 1. High pouring temperatures. 1. Regulate pouring temperature.
2. Gas dissolved in metal charge. 2. Control metal composition.
3. Less flux used. 3. Increase flux proportions.
4. Molten metal not properly degassed. 4. Ensure effective degassing.
5. Slow solidification of casting. 5. Modify gating and risering.
6. High moisture and low permeability
Misruns 1. Lack of fluidity ill molten metal. 1. Adjust proper pouring
2. Faulty design. temperature.
3. Faulty gating. 2. Modify design.
3. Modify gating system.
Hot Tears 1. Lack of collapsibility of core. 1. Improves collapsibility of core
2. Lack of collapsibility of mold. and mold.
3. Faulty design. 2. Modify casting design.
4. Hard ramming of mold.
Metal 1. Large grain size and used. 1. Use sand having finer grain size.
penetration 2. Soft ramming of mold. 2. Provide hard ramming.
3. Molding sand or core has low strength. 3. Suitably adjustt pouring
temperature.
Cold shuts 1. Lack of fluidity in molten metal. 1. Adjust proper pouring metal.
2. Faulty design. 2. Modify design.
3. Faulty gating 3. Modify gating system.
Cuts and 1. Low strength of mold and core. 1. Improve mold and core strength.
washes 2. Lack of binders in facing and core 2. Add more binders to facing and
stand. core sand.
3. Faulty gating. 3. Improve gating.
Inclusions 1. Faulty gating. 1. Modify gating system.
2. Faulty pouring. 2. Improve pouring to minimize
3. Inferior molding or core sand. turbulence.
4. Soft ramming of mold. 3. Use of superior sand of good
5. Rough handling of mold and core. strength.
4. Provide hard, ramming.
Fusion 1. Low refractoriness in molding sand. 1. Improve refractoriness of sand.
2. Faulty gating. 2. Modify gating system.
3. Too high pouring temperature of the 3. Use Lower pouring temperature.
metal. 4. Improve the quality of facing
4. Pouring facing sand. sand
Drops 1. Low green strength in molding sand 1. Increase green strength of sand
and core. mold.
2. Too soft ramming. 2. Provide harder ramming.
3. Inadequate reinforcement of sand and 3. Provide adequate reinforcement
core projections. to sand projection and cope by
using nails and gaggers.
Shot metal 1. Too low pouring temperature. 1. Use proper pouring temperature.
2. Excess sulphur contests in metal. 2. Reduce sulphur content.
3. Faulty gating. 3. Modify gating of the system
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4. High moisture content in molding sand

Shift 1. Worn-out or bent clamping pins. 1. Repair or replace the pins, for
2. Misalignments of two halves of pattern. removing the defect.
3. Improper support of core. 2. Repair or replace dewels with
cause misalignment.
3. Provide adequate support to the
core.
4. Increases strength of both mold
and core.
Crushes 1. Defective core boxes producing over- 1. Repair or replace the pins, for
sized cores. removing the defect.
2. Worn out core prints on patterns 2. Repair or replace dowels with
producing undersized seals for cores in cause misalignment.
the mild.
3. Careless assembly of cores in the mold.
Rat-tails or 1. Continuous large flat surfaces on 1. Break continuity of large flat
buckles casting. grooves and depressions.
2. Excessive mold hardness. 2. Reduce mold hardness.
3. Lack of combustible additives in 3. Add combustible additives to
molding sand. sand.
Swells 1. Too soft ramming of mold. 1. Provide hard ramming.
2. Low strength of mold and core. 2. Increase the strength of both
3. Mold not properly supported mold and core.
Hard spot 1. Faulty metal composition. 1. Suitable charge metal
2. Faulty casting design. composition.
2. Modify casting design.
Run out, 1. Faulty molding. 1. Improving molding techniques.
Fins and 2. Defective molding boxes. 2. Change the defective molding
Fash boxes.
3. Keep weights on mold boxes.
Spongings 1. Availability of dirt and swarf held in 1. Remove dirt dwarf held in
molten metal. molten metal.
2. Improper skimming. 2. Skimming should be perfect.
3. Because of more impurities in molten 3. Fewer impurities in molten
metal. metal should be there.
Warpage 1. Continuous large flat surfaces on 1. Follow principle of sufficient
castings are indicating a poor design. directional solidification.
2. No dimensional solidification of 2. Make good castings design
casting.

IV.CONCLUSION pecentage reduction, productivity improvement,yield

improvementand simultaneously the cost saving
In this paper an effort has been done to enable detailing increasing profitability of organization.
the steps involved in casting manufacturing process and
co-relating issues related to these steps leading to REFERENCES
defects .Defects are generated mainly due to poor
Harshwardhan Pandit , “ WebCADAS: A New
[1]
process control.By conducting brain storming activity ,
Online Education System for Casting Defect
involving cross functional teams ,defects identification
Identification, Analysis and Optimisation of
can be done more effectively as a team work.It can help
Parameters ”, IJLTET Vol. 5 Issue 4 July 2015
casting manufacturer control issue of rejection
ISSN: 2278-621X
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[2] P. Sathish Kumar , A. Ramesh , and M. [5] A.P.More ,,Dr.R.N.Baxi,,Dr.S.B.Jaju , “

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Casting Defects ” ARPN Journal of
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Foundry and Their Remedial Measures with
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