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Lab 2 Discussion

This document discusses product defects found in metal casting and methods to prevent them. It describes cuts and washes, which are areas of excess metal caused when molten metal erodes the molding sand. Cuts and washes can be prevented by properly designing the gating system, improving mold and core strength, and adding more binders to the sand. The document also notes that aluminum was used as the material for casting due to its low melting temperature, high freezing temperature, and lightweight yet durable properties.

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MUHAMMAD ALIFF HAIKAL BIN SHOLAHUDIN STUDENT
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27 views

Lab 2 Discussion

This document discusses product defects found in metal casting and methods to prevent them. It describes cuts and washes, which are areas of excess metal caused when molten metal erodes the molding sand. Cuts and washes can be prevented by properly designing the gating system, improving mold and core strength, and adding more binders to the sand. The document also notes that aluminum was used as the material for casting due to its low melting temperature, high freezing temperature, and lightweight yet durable properties.

Uploaded by

MUHAMMAD ALIFF HAIKAL BIN SHOLAHUDIN STUDENT
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Discussion

Product Defects

Casting defect is an undesired irregularity in a metal casting process. Some defects can be
tolerated while others can be repaired, otherwise they must be eliminated.

One of the defects we found on our experiment is cuts and washes. Cuts and washes are areas
of excess metal. These appear when the molten metal erodes the molding sand.

A cut appears as a low projection along the surface of the drag face, decreasing in height as it
extends from one side of the casting to the other.
Causes and prevention of cuts and washes

Cuts and washes can be caused by molten metal flowing at a high velocity, causing too much
metal to flow through the gate.

We can prevent cuts and washes easiest by:

 Designing the gating system properly


 Improving mold and core strength
 Adding more binders to the facing and core sand

Example of Gas Porosity

Example of Cut and Washes


Material Used

In this experiment we use aluminum as the material for our final product. The reason to use
aluminum as the material are:

1. Low melting temperature (approximately 655oC)


2. High freezing temperature (approximately between 115.556oC to 237.778oC)
3. Non-corrosive.
4. Lightweight yet durable.

So, with that reason we decided to use carbon as the material of the container to melt the
aluminum. This is because the melting point or temperature for carbon are way higher than
the aluminum which is 3550oC.

During the experiment, the lecturers decided to decrease the temperature of the furnace from
850oC to 750oC. the lecturers decided to do that after we are taking too much times to prepare
the mold. Also, to note that, keeping the temperature at a constant level during the pour is
vital to ensure the integrity of the finished product. If the molten metal is too hot, this will
alter the chemical and physical properties and the casting will not meet the required
specifications. If the temperature is too low, the molten metal will not flow into all the
cavities and apertures of the casting due to solidification. So, the temperature is monitored
carefully.

Lastly, we use the parting powder to coats the surface of a pattern so that the molding sand
will not stick to it after we separate two parts of the molding.

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