Professional Documents
Culture Documents
Type 1:
Defects ,which can be ascertained during visual inspection or
measurement
Type2:
Defects, which can be ascertained only after Machining, Sectioning
or Radiography
Type3:
Defects, which can be ascertained only during Mechanical testing,
Micro structure examination.
Type 1:
1.
External shrinkage (Surface shrinkage)
2.
Cross defects
3.
Open blow holes
4.
Pin holes
5.
Rough surface
6.
Cold shuts
7.
Scabbing
Type2:
1.
2.
3.
4.
Internal shrinkages
Core broken/Blockage/Core warp age
Blow holes
Carbon floatation
Type3:
1.
2.
3.
4.
Poor Microstructure
Undesired Metallurgical properties
Undesired Mechanical properties
Undesired chemical composition
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
SHRINKAGE
PHENOMENON OF SHRINKAGE:
When the molten metal solidifies, the atoms in the
molten metal attract each other and get a compacted
form, which results the volumetric contraction.
Stages of Shrinkage
1.Liquid Shrinkage (Primary Shrinkage) - Shrinkage is about
3%- 4%
2.Solidification Shrinkage (Secondary Shrinkage) Shrinkage
is about 2%- 3%
3.Solid Shrinkage or Contraction. Shrinkage is about 0.5%
-1%.
Practically Liquid shrinkage and Solidification shrinkage of
molten metal will be about 6%.
Volumetric Contraction
Theoretical
Temperature of the liquid
After pouring
Primary Contraction
Volume
( Liquid Shrinkage)
Secondary shrinkage
(Solidification shrinkage)
Solid contraction
Practical
Temperature
TYPES OF SHRINKAGE:
1.Surface shrinkage
2.Internal shrinkage
Porosity-Micro porosity
Spongy shrinkage
SHRINKAGE
ROOT CAUSES:
1.Insufficient feeder (riser).
2.Insufficient riser neck.
3.More ingate thickness.
METHOD OF RECTIFICATION
1.ROOT CAUSE:-Insufficient Riser.
Remedial Action
1.Increase the riser modulus.
2.Increase the feed safety margin.
3.Reduce the feeding distance of the
riser.(<2t) t: thickness of the plate.
4.Providing chills.
Remedial Action
1.Increase the rate of pouring.
2.Increase the ingate area./Choke area.
3.Increase the pouring temperature to the maximum
possible level.
4.Increase the phosphorus content but it should be <0.1.
SHORT POURING
GAS DEFECTS:
Gas defects (blow holes)are generated due
to absorption of gases by the molten metal
during metal pouring or the evolution of the
gases from the cores after completion of
pouring.
GAS DEFFECT
ROOT CAUSES :
1.Poor gating design will induce turbulence in metal flow
2.Insufficient gas outlets
3.Improper sprue and gate design will allow the air aspiration.
4.High moisture content in the sand
5.Low permeability of sand.
6.Presence of more volatile materials
7.Poor mixing of sand.
8.Usage of excessive coating materials
9.Excess Nitrogen content in the binding material.
10.Inadequate curing of cores.
11.Gases dissolved in the molten metal.
12.Greasy or rusty scraps for melting.
13.Low pouring temperature
14.Poor pre-treatment of pouring/treatment ladles.
15.Slow Pouring.
METHOD OF RECTIFICATION
1.Gating system should be designed in such a way that it minimizes the air
aspiration.
2.Avoid abrupt changes in the gating system.
3.Provide gas out lets wherever possible.
4.Moisture content in the mould to be controlled.
5.If possible, avoid using more fine sand.
6.Content the volatile materials in the moulding sand within 3%.
.Sand mixing should be uniform (homogeneous) mix .
8.Excessive coating materials will evolve the gas when it contacts the
molten metal. So excessive coating should be avoided.
9.Less cured / uncured cores will evolve more gases after completion of
molten metal. So cores should be cured well.
PIN HOLES
This defect is often seen in grey iron castings but also occurs
in nodular cast irons .
Pin holes are normally present just below the casting face.It
will reveal after shot blasting.
Nitrogen pinholes are found usually at the hot spots whereas
the Hydrogen pin holes are found in the areas remote to the
ingate.
PIN HOLES
ROOT CAUSES
METHOD OF RECTIFICATION
1.Establish the safer amount of Mg.Si & Al content.
2.Ensure the sufficient amount of volatile and moisture content in the
moulding sand.
3.Avoid long and complex running system.
4.Nitrigen content to be contained in the resin bonded cores.
CARBON FLOATATION
When the Carbon equivalent is as high as 4.5%,carbon
floatation will takes place at the h3eavier sections, due to slow
cooling rate.
Localized hot spots at the gate or riser function may slow
down the cooling to the point that gross segregation is found in
the gate function or riser neck.
Incorrect of use of exothermic insulating moulding materials
causes localized over heating and slow down the cooling.
Very high melting temperature.
CARBON FLOATATION
ROUGH SURFACE:
Lackness in degree of smoothness
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
ROOT CAUSE:
Pattern equipment with in accessible areas for moulding sand.
Too small fillet /edge radius.
Very high velocity of Molten metal will erode the mould wall.
Sand with too high or too low moisture.
Too coarse grain size of moulding sand.
Improper Sand preparation.
Poor ramming of coarse.
Insufficient coating of coarse.
Over cured cores.
Uneven or insufficient coating or spraying of moulds.
Very high pouring temperature.
METHOD OF RECTIFICATION
1. pattern equipment should be designed with adequate drafts,
surface finish , edge radii, fillet radii.
2. Non pressurized gating system is preferable.
3. Ensure the adequate quality of sand.
4. Ensure the fineness of the sand.
5. Ensure uniform coating of cores.
6. Ensure sufficient curing.
7. Avoid very high pouring temperature.
SAND DROP:
It is a defect due to dropping of the Sand from
the cope or other area of the mould.
ROOT CAUSE:
It is due to carelessness of the operator or because of rough
handling.
In adequate mould relieving draft induce the mould crack and
facilitate sand drops.
Weak or lose flask bars cause mould distortion will get crack
during moulding.
Misalignment of moulds.
Inadequate green strength, impact strength, tensile strength,
shear strength and deformation properties of the moulding sand.
Inadequate dry strength for dry sand moulding.
MIS RUN
It is a defect which has a lack in completeness of
the molten metal during metal filling
COLD SHUTS
COLD SHUTS
ROOT CAUSE:
1. Non uniform casting sections resulting interrupted metal flow.
2. Very thin In gates.
3. Low pouring temperature.
4. Inadequate gas outlets.
5. high volatile matter in the moulding sand.
6. Low permeability of sand.
7. Low carbon equivalent-due to low fluidity.
8. Very low phosphorous content.
9. Interrupted pouring.
10.Inadequate pressure head.
11.Short pouring.
12.Very slow pouring.
METHOD OF RECTIFICATION
1.
2.
3.
4.
5.
6.
DROSS DEFECTS :
It is nothing but the inclusions of the
metallic oxides.
Ductile iron is very prone for this defect
rather than gray iron.
ROOT CAUSES:
1.High Magnesium /Aluminium and Sulphur
content in the molten metal.
2.Turbulence in the flow of metal.
3.Poor de-sulphurisation methods.
4.Sulphur bearing materials in the moulding
materials.
5.Low pouring temperature.
METHOD OF RECTIFICATION
a.Melting.
1.Maintain a low sulphur in the base metal.
2.Add minimum possible Magnesium / Magnesium alloy.
3.Maintain carbon equivalent nearer to 4.3%.High carbon
equivalent will create segregation of graphite nodules at the
upper surface of casting during solidification which
aggravates the dross defects.
4.Avoid use of alloys containing Aluminium in amounts
higher than the requirement to achieve the necessary
inoculation properties.
5.Effective de-sulphurisation.
b.Moulding
c.Gating
1.Avoid abrupt changes in the gating system
to reduce the turbulence.
2.The ratio of the Down sprue : Runner
bar : ingate can be 1.0 :1.06:1.15.
d.Metal Pouring
1.Avoid pouring of cold metal.
2.Lining the ladles with frequent intervals.
3.Skim the molten metal effectively to hold back
the slag.
SCABBING
It is a defect in which the loosened sand has
been eroded away by the motion of metal
while pouring
SCABBING
PHENOMENON
When the metal enters into the mould
cavity heat is radiated to the top and side
walls of the mould. So the mould starts
disintegrated. When metal touches the
mould wall it penetrates into the weak
mould wall
ROOT CAUSE
1.Poor ramming of mould
2.High moisture content in the moulding sand
3.Poor quality of binding material
4.Slow pouring
5.Insufficient-Ingates
6.Excessive pouring temperature