DELHI TECHNOLOGICAL

UNIVERSITY
CASTING DEFECTS

2K13/PE/047 VIPIN
2K12/PE/011 DIPALI RANJAN
2K14/PE/501 DHARMENDRA

Casting D efects
Metal casters try to produce perfect

castings.

A few castings, however, are completely

free of defects.

Modern foundries have sophisticated

inspection equipment which can detect

small differences in size and a wide variety
of external and even internal defects.
For example, slight shrinkage on the back of
a decorative wall plaque is acceptable
whereas similar shrinkage on a position
cannot be tolerated.

No matter what the intended use, however,

 Scrap castings cause much concern.

In industry, scrap results in smaller profits for the

company and ultimately affects individual wages.

Scrap meetings are held daily. Managers of all the major

departments attend these meetings. They gather castings
that have been identified as scrap by inspector. The defect is
circled with chalk. An effort is made to analyze the cause of
the defect, and the manager whose department was
responsible for it is directed to take corrective action to
eliminate that specific defect in future castings.

There are so many variables in the production of a

metal casting that the cause is often a combination of

several factors rather than a single one.

All pertinent data related to the production of the

casting (sand and core properties, pouring

temperature) must be known in order to identify the
defect correctly.

After the defect is identified attempt should be to

CASTING DEFECTS
SURFACE

METALLIC PROJECTION
Swell, Crush, Mould Drop, Fillet Vein
DEFECTIVE SURFACE
Erosion Scab, Fusion, Expansion Scab,
Rat tails, Buckle, Seams, Gas Runs, Fillet
Scab, Rough Surface, Slag Inclusion,
Elephant Skin
CHANGE IN DIMENSIONWarped casting
INCOMPLETE CASTINGMisrun, Run out
CAVITYBlow Holes, Shrinkage cavity, Pinholes
DISCONTINUITYHot Cracking, Cold Shut, Cold Cracking

SUBSURFACE
SUBSURFACE CAVITYBlow Holes, Pin Holes,
Shrinkage
Porosity, Internal
Shrinkage, Severe
Roughness
INCLUSIONSGas Inclusions, Slag, Blow
Holes
DISCONTINUITYCold Shuts
NITC

Repairability

FINS OR FLASH ON CASTINGS -AsMetallic

Projections
Joint flash or fins. Flat projection of irregular

thickness, often with lacy edges, perpendicular to

one of the faces of the casting. It occurs along
the joint or parting line of the mold, at a core
print, or wherever two elements of the mold
intersect.
Possible Causes
Clearance between two elements of the mold or
between mold and core;
Poorly fit mold joint.
Remedies
Care in pattern making, molding and core
making;
Control of their dimensions;

Flask was disturbed while investment was setting.

Base was removed too soon.
Flask was allowed to partially dry before dewaxing.
Incorrect dewaxing or a furnace malfunction.
Flask burned out and allowed to cool below (260oC)
before casting reheating, flask allowed to cool
between dewax and placement in preheated oven.
Flask was improperly handled or dropped.
Speed was set too high on centrifugal casting
machine.
Patterns were placed on one plane. The should be
staggered on top rack.
Incorrect water powder ratio was used.
Not enough investment was placed over the
patterns.
Flask was placed too close to heat source in burnout
oven.

DEFECTS IN CASTINGS- CAN BE ELIMINATED/MINIMISED

BY PROPER DESIGN, MOLD PREPARATION, PROPER
POURING.
NITC

DEFECTS IN CASTINGS- AS HOT TEARS - DUE TO

CONSTRAINTS IN LOCATIONS, CASTINGS
CANNOT SHRINK FREELY
NITC

Cavities
Blowholes, pinholes. Smooth-walled

cavities, essentially spherical, often not

contacting the external casting surface
(blowholes). The largest cavities are most
often isolated; the smallest (pinholes)
appear in groups of varying dimensions.
The interior walls of blowholes and
pinholes can be shiny, more or less
oxidized or, in the case of cast iron, can be
covered with a thin layer of graphite. The
defect can appear in all regions of the
casting.

 Possible Causes
Because of gas entrapped in the metal during the course of

solidification:
Excessive gas content in metal bath (charge materials,
melting method, atmosphere, etc.); Dissolved gases are
released during solidification.

In steel and cast irons: formation of carbon monoxide by

the reaction of carbon and oxygen, presents as a gas or in

oxide form. Blowholes from carbon monoxide may increase
in size by diffusion of hydrogen or, less often, nitrogen.

Excessive moisture in molds or cores.

Core binders which liberate large amounts of gas.
Excessive amounts of additives containing hydrocarbons.
Blacking and washes which tend to liberate too much gas.
Insufficient evacuation of air and gas from the mold cavity;
-insufficient mold and core permeability.
Entrainment of air due to turbulence in the runner system.

 Remedies
Make adequate provision for evacuation of

air and gas from the mold cavity

Increase permeability of mold and cores
Avoid improper gating systems
Assure adequate baking of dry sand molds
Control moisture levels in green sand
molding

Reduce amounts of binders and additives

used or change to other types; -use

blackings and washes, which provide a
reducing atmosphere; -keep the spree
filled and reduce pouring height

Increase static pressure by enlarging

Discontinuities
Hot cracking. A crack often scarcely visible because the

casting in general has not separated into fragments. The

fracture surfaces may be discolored because of oxidation.
The design of the casting is such that the crack would not
be expected to result from constraints during cooling.

Possible Causes
Damage to the casting while hot due to rough handling or

excessive temperature at shakeout.

Remedies
Care in shakeout and in handling the casting while it is still

hot;
Sufficient cooling of the casting in the mold;
For metallic molds; delay knockout, assure mold alignment,
use ejector pins

Defective Surface
Flow marks. On the surfaces of otherwise sound

castings, the defect appears as lines which trace the

flow of the streams of liquid metal.

Possible Causes
Oxide films which lodge at the surface, partially

marking the paths of metal flow through the mold.

Remedies
Increase mold temperature;
Lower the pouring temperature;
Modify gate size and location (for permanent
molding by gravity or low pressure);
Tilt the mold during pouring;
In die casting: vapor blast or sand blast mold
surfaces which are perpendicular, or nearly
perpendicular, to the mold parting line.

Incomplete Casting
Poured short. The upper portion of the casting is

missing. The edges adjacent to the missing section

are slightly rounded, all other contours conform to
the pattern. The spree, risers and lateral vents are
filled only to the same height above the parting
line, as is the casting (contrary to what is observed
in the case of defect).

Possible Causes
Insufficient quantity of liquid metal in the ladle;
Premature interruption of pouring due to

workmans error.

Remedies
Have sufficient metal in the ladle to fill the mold;
Check the gating system;

Incorrect Dimensions or Shape

Distorted casting. Inadequate thickness,
extending over large areas of the cope or drag
surfaces at the time the mold is rammed.
Possible Causes
Rigidity of the pattern or pattern plate is not

sufficient to withstand the ramming pressure

applied to the sand. The result is an elastic
deformation of the pattern and a corresponding,
permanent deformation of the mold cavity. In
diagnosing the condition, the compare the
surfaces of the pattern with those of the mold
itself.

Remedy
Assure adequate rigidity of patterns and pattern

Inclusions or Structural Anomalies

Metallic Inclusions. Metallic or intermetallic inclusions of various

sizes which are distinctly different in structure and color from the
base material, and most especially different in properties. These
defects most often appear after machining.

Possible Causes
Combinations formed as intermetallics between the melt and metallic
impurities (foreign impurities);
Charge materials or alloy additions which have not completely
dissolved in the melt;
Exposed core wires or rods;
During solidification, insoluble intermetallic compounds form and
segregate, concentrating in the residual liquid.

Remedies
Assure that charge materials are clean; eliminate foreign metals;
Use small pieces of alloying material and master alloys in making up
the charge;
Be sure that the bath is hot enough when making the additions;
Do not make addition too near to the time of pouring;
For nonferrous alloys, protect cast iron crucibles with a suitable wash

 INCLUSIONS (FOREIGN PARTICLES) IN CASTINGS

Patterns were improperly sprued to wax base or tree

or not filleted, causing investment to break at sharp

corners during casting.
Flask was not sufficiently cured before placing into
burnout oven.
Improper dewaxing cycle was used.
Flask was not cleaned from prior cast.
Loose investment in sprue hole.
Molten metal contains excess flux or foreign oxides.
Crucible disintegrating or poorly fluxed.
Improperly dried graphite crucible.
Investment was not mixed properly or long enough.
Contaminants in wax pattern.
Flask was not held at low burnout temperature long
enough.

 POROSITY
Pattern is improperly sprued. Sprues may

be too thin, too long or not attached in the

proper location, causing shrinkage
porosity.
Not enough metal reservoir to eliminate
shrinkage porosity.
Metal contains gas.
Mold is too hot.
Too much moisture in the flux.
Too much remelt being used. Always use
at least 50% new metal.
Metal is overheated.
Poor mold burnout.

 ROUGH CASTINGS
A poor quality pattern
Flask was not sufficiently cured before

placing into burnout oven.

Flask was held in steam dewax too
long.
Metal, flask or both were too hot.
Patterns were improperly sprued.
Flask was placed too close to heat
source in burnout oven.

 BUBBLES OR NODULES ON

CASTINGS
Vacuum pump is leaking air.
Vacuum pump has water in the oil.
Vacuum pump is low on oil.
Investment not mixed properly or long
enough.
Invested flasks were not vibrated
during vacuum cycle.
Vacuum extended past working time.

 SPALLING (an area of the mold wall

flakes into the mold cavity)

Flask was placed into a furnace at low
temperature (below 150oC) for an
extended period.
Flask was placed too close to the
source of heat.
Sharp corners are struck by metal at
high centrifugal velocities.
Improper burnout cycle was used.

 NON-FILL OR INCOMPLETE

CASTINGS
Metal was too cold when cast.
Mold was too cold when cast.
The burnout was not complete.
Pattern was improperly sprued,
creating turbulence when casting in a
centrifugal casting machine.
Centrifugal casting machine had too
high revolution per minute.

 GROWTH-LIKE ROUGH CASTING

THAT RESISTS REMOVAL IN

PICKLING SOLUTION
Burnout temperature too high.
Mold temperature was too high when
casting.
Metal temperature was too high when
casting.

 SHINY CASTINGS
Carbon residue was left in the mold,

creating a reducing condition on the

surface.

AVERAGE SURFACE ROUGHNESS VALUES BY

VARIOUS PROCESSES

NITC

DESIGN CONSIDERATIONS
CAREFUL CONTROL OF LARGE NUMBER OF
VARIABLES NEEDED
CHARACTERISTICS OF METALS & ALLOYS
CAST

METHOD OF CASTING

MOULD AND DIE MATERIALS

MOULD DESIGN

PROCESS PARAMETERS- POURING,

TEMPERATURE,

GATING SYSTEM

RATE OF COOLING Etc.Etc.

NITC

 Poor casting practices, lack of control of process

variables- DEFECTIVE CASTINGS
TO AVOID DEFECTS Basic economic factors relevant to casting operations to
be studied.
General guidelines applied for all types of castings to be
studied.

DESIGN CONSIDERATIONS

NITC

CORNERS, ANGLES AND SECTION THICKNESS

Sharp corners, angles, fillets to be avoided
Cause cracking and tearing during solidification
Fillet radii selection to ensure proper liquid metal flow3mm to 25 mm.
Too large- volume large & rate of cooling less
Location with largest circle inscribed critical.
Cooling rate less
shrinkage cavities & porosities resultCalled HOT SPOTS

NITC

DESIGN MODIFICATIONS TO AVOID DEFECTS

AVOID SHARP CORNERS

MAINTAIN UNIFORM CROSS SECTIONS
AVOID SHRINKAGE CAVITIES
USE CHILLS TO INCREASE THE RATE OF COOLING
STAGGER INTERSECTING REGIONS FOR
UNIFORM CROSS SECTIONS
REDESIGN BY MAKING PARTING LINE STRAIGHT
AVOID THE USE OF CORES, IF POSSIBLE
MAINTAIN SECTION THICKNESS UNIFORMITY
BY REDESIGNING (in die cast products)

NITC

 LARGE FLAT AREAS TO BE AVOIDED

WARPING DUE TO TEMPERATURE GRADIENTS

ALLOWANCES FOR SHRINKAGE TO BE PROVIDED
PARTING LINE TO BE ALONG A FLAT PLANEGOOD AT CORNERS OR EDGES OF CASTING
DRAFT TO BE PROVIDED
PERMISSIBLE TOLERANCES TO BE USED
MACHINING ALLOWANCES TO BE MADE
RESIDUAL STRESSES TO BE AVOIDED
ALL THESE FOR EXPENDABLE MOULD CASTINGS.

NITC

DESIGN MODIFICATIONS TO AVOID DEFECTSAVOID SHARP CORNERS TO REDUCE STRESS

CONCENTRATIONS
NITC

DESIGN MODIFICATIONS TO AVOID DEFECTSMAINTAIN UNIFORM CROSS SECTIONS TO AVOID HOT

SPOTS AND SHRINKAGE CAVITIES
NITC

DESIGN MODIFICATIONS TO AVOID DEFECTSGOOD DESIGN PRACTICE

NITC

DESIGN MODIFICATIONS TO AVOID DEFECTSSTAGGERING OF INTERSECTING REGIONS

NITC

DESIGN MODIFICATIONS TO AVOID DEFECTSSECTION THICKNESS UNIFORMITY MAINTAINED

THROUGHOUT PART
NITC

DESIGN MODIFICATIONS TO AVOID DEFECTS

NITC

DESIGN MODIFICATIONS TO AVOID DEFECTSUSE OF METAL PADDING (CHILLS)

TO INCREASE RATE OF COOLING

NITC

DESIGN MODIFICATIONS TO AVOID DEFECTSMAKING PARTING LINE STRAIGHT

NITC

DESIGN MODIFICATIONS TO AVOID DEFECTSIN DESIGN

NITC

INSPECTION OF CASTINGS

SEVERAL METHODS
VISUAL
OPTICAL
- FOR SURFACE DEFECTS
SUBSURFACE AND
INTERNAL DEFECTS
THROUGH

NDTs & DTs

PRESSURE TIGHTNESS OF
VALVES BY SEALING THE
OPENING AND
PRESSURISING WITH WATER

EXERCISE

PROCESS FLOW CHART

RECEIPT OF ORDER
(REVIEW)
ARE THE TERMS ACCEPTED? NO
COMMUNICATENEGOTIATE
YES
PREPARE WORK ORDER
WORK ORDER TO Q.C, INSPECTION, PLANNING, METHODS,
PRODUCTION AND DESPATCH

PRODUCTION PLAN
METHOD DRAWING, QA DATA, PATTERN PLAN
MOULDING
WORK ORDER, CORE MAKING, HEAT CONFORMATION
MELTING AND POURING
FOR THESE, LAB TEST REPORTS
KNOCK OUT
STAGE ISPECTION- NOT OK, REJECT
OK, SHOT BLASTING, GAS CUTTING/ARC CUTTING
ASTM STANDARDS

HEAT TREATMENT
ROUGH FETTLING, FINISH FETTLING,

INSPECTION

 NDT- CUSTOMER REPORT, NOT OK,

WELDING & RECTIFICATION

WELDING LOG SHEET

RE-INSPECTION, NOT OKREJECT
MACHINE - IF REQUIRED
STRESS RELIEF
HYDRAULIC TESTS Etc.
TEST CERTIFICATE DESPATCH
DOCUMENTS, PACKING, Etc. Etc.

NEWS FROM NET

Largest Vertically Parted Mold Machine Built

for Denmark.
DISA Group (with U.S. headquarters in Oswego,
Illinois) received a contract for the delivery of a
jumbo-sized DISA 280B vertical green sand
molding system.
Molds measure 850 x 1200 mm, making it the
largest vertically parted green sand molding
system ever produced.
This new jumbo-sized molding system provides a
space-saving, high-capacity and high-quality
alternative to conventional horizontal molding
lines.

NEWS FROM NET

It works on the vertically parted molding principle

of blowing green sand into the mold chamber,
which is subsequently squeezed into flaskless
molds. In the inaugural installation, the DISA 280B
is replacing a horizontal green sand molding line of
a similar flask/box size. The foundry is making the
switch from its existing horizontal molding
arrangement to the large-scale vertically parted
machine to gain competitiveness through
productivity gains and enhanced casting quality.
These improvements are fundamental to the
foundrys success in its market sector.

NEWS FROM NET

The MM Casting Process

Design Considerations Metal Specifications
Tooling Machining
Supply of Design Information Inspection / Quality
Assurance
Case Studies - Automobile Telephone Chassis - Cassette Slide
Ratchet - Casting for Satellite TV - Clamp - Computer Data
Backup System - Gauge Body - Hand Held Breathalyzer Light Shield - Regulator Valve - Roller Carrier Slide Small Metal Connectors - Switch Gear - Twister
MM-Micro Metalsmiths in the field of Investment casting

NEWS FROM NET

The contract includes the design and changeover

of existing horizontal patterns to a vertical
orientation. This assures that the foundry will be
able to continue to use more than 98% of its
existing patterns. The foundry expects to begin
production without any compatibility problems as
the new line takes the same position of the
existing mold line on the foundry floor.
.

NEWS FROM NET

The MM casting process

Precision investment casting process
The aim of this guide is to enable the designer to take advantage
of the technical and commercial benefits offered by the MM
casting process. Also included in the guide are design ideas and
considerations to help and stimulate the design process.

NEWS FROM NET

Micro Metalsmiths continues to develop its process so as

to meet ever more exacting market challenges.
For over thirty years Micro Metalsmiths has refined its
techniques for excellence in the production of copper
and aluminium alloy investment castings.
Micro Metalsmiths has combined its impressive
investment casting technology with best practice CNC
machining, so allowing many of the constraints placed
on engineering design to be overcome.
All this is carried out within a BSI accredited ISO 9001
Quality System.

NEWS FROM NET

Why use the MM casting process

Reduce overall costs by Designing for Manufacture:
simplify an assembly by combining a number of parts:
eliminate joining processes: reduce the part count
whilst improving the integrity of the finished product.
Reduce time to market through use of Rapid
Prototyping technology and obtain casting, machining,
assembly and packaging from one source. Finished
metal parts are deliverable from concept in less than
four weeks.
Design flexibility, with quick modifications to tooling
that costs 90% less than for a pressure die casting,
whilst maintaining economic batch quantities of up to
500,000 parts per annum.

NEWS FROM NET

What the MM casting process can deliver:

High quality finish, detail and specification. Thin
walls as fine as 0.2 mm, typically 1-3 mm.
Light weight components, weighing as little as 1g
can be produced using techniques to minimise
material usage whilst retaining component
integrity.
Maximum size of 190 mm x 160 mm x 160 mm. A
length of 250 mm is possible providing no other
dimension exceeds 100mm.
Complex detail on internal and external features.
Superfine surfaces with 0.8 micrometres being the
as cast finish.
Zero draft angles

NEWS FROM NET

The Sure-Trak shot control system is a realtime, all digital, closed-loop system to
increase die-casting quality. Mercury
Castings has seen success in reducing air
entrapment during the slow shot phase on a
variety of parts, including these outboard
engine covers
www.moderncasting.com/info