UNIT-2

SPECIAL CASTING METHODS

Permanent Mold Casting
•Also known as metal mold casting, it is a casting method in which
liquid metal is poured into a metal mold to obtain a casting. The
mold is made of metal and can be used repeatedly (hundreds to
thousands of times), also known as permanent casting.
•Generally, metal molds are made of cast iron and cast steel. The
inner cavity of the casting can be either a metal core or a sand core.
There are many types of metal types, such as horizontal type, heavy
straight type, and composite type.
•The vertical parting is convenient for opening the gate and taking
out the castings; the horizontal parting is mostly used to produce
thin-walled wheel-shaped castings; the upper part of the composite
parting is formed by the two parts of the vertical parting using
hinges, and the lower part It is a fixed horizontal bottom plate,
mainly used in the casting of more complex castings.
permanent mold casting process consists of the following steps:
Mold preparation - First, the mold is pre-heated to around 300-
500°F (150-260°C) to allow better metal flow and reduce defects.
Then, a ceramic coating is applied to the mold cavity surfaces to
facilitate part removal and increase the mold lifetime.
Mold assembly - The mold consists of at least two parts - the two
mold halves and any cores used to form complex features. Such
cores are typically made from iron or steel, but expendable sand
cores are sometimes used. In this step, the cores are inserted and the
mold halves are clamped together.
Pouring - The molten metal is poured at a slow rate from a ladle
into the mold through a sprue at the top of the mold. The metal
flows through a runner system and enters the mold cavity.
Cooling - The molten metal is allowed to cool and solidify in the
mold.
Mold opening - After the metal has solidified, the two mold halves
are opened and the casting is removed.
Trimming - During cooling, the metal in the runner system and sprue
solidify attached to the casting. This excess material is now cut away.
Advantages of permanent mold casting process
•Better mechanical properties.
•Homogeneous grain structure and chemical composition.
•Low shrinkage and gas porosity.
•Good surface quality: 40-250 µinch (1-6 µm) Ra.
•Low dimensional tolerances: typically about 0.04” (1 mm}.
•Little scrap process.
Disadvantages of permanent mold casting:
•High cost of the molds.
•Limitations in casting of high melting point metals into metallic
molds.
•Intrinsic and complex shapes can not be cast.
•Large parts can not be cast.
Die casting is an efficient method of creating a broad range of
shapes, die castings are one of the most mass produced components
today and are found in many items in and around the home. Many
toy cars use die casting in their production, as do real vehicles. Die
casting offers high accuracy in its products with a good quality
surface finish which is suitable for many products without the need
for extra polishing or machining.
Hot chamber die casting is a type of die casting that uses alloys with
low melting temperatures (i.e. Zinc, some Magnesium alloys). Using
alloys with high melting temperatures would result in damage to the
gooseneck, nozzle, and other components.
In a hot chamber die casting machine, the fixed die half is called a
cover die, which is mounted to a stationary platen (large plate to
which each die half is mounted) and aligns with the nozzle of the
gooseneck. The movable die half is the ejector die and is mounted to
a movable platen, which slides along tie bars.
The metal is contained in an open holding pot, which is placed in the
furnace and melted to the needed temperature. When the plunger
is in the “up” position, the molten metal flows into the shot
chamber. As the plunger moves down, it forces the molten metal
through a gooseneck and into the die at injection pressures ranging
from 1,000 – 5,000 psi.
The machine pushes the moving platen towards the cover die and
holds it closed with great pressure until the molten metal is
injected. The plunger remains in the “down” position to hold the
pressure while the casting “cools off.” After solidification, the
plunger is retracted and the cast part is either ejected, manually
removed from the machine or pushed off the cover die. This
ejection system, which includes an ejector die and ejector pins,
allows the casting to be pushed out while releasing the die halves.
Cold chamber die casting is a type of die casting that is used for
alloys with high melting temperatures (i.e. Aluminum and
some Magnesium alloys).
•As a contrast from hot chamber die casting (pumping molten metal
into the machine), molten metal is ladled from the furnace into the
shot chamber through a pouring hole. While the general function of
the cold chamber machine is similar to hot chamber, cold chamber
works with a horizontal orientation and does not have a gooseneck.
•Instead, the plunger forces metal through the shot chamber into
the die at pressures ranging from 2,000 and 20,000 psi. The plunger
holds the pressure and retracts after solidification. The clamping unit
and mounting of dies is set up the same as hot chamber, however, the
cover die for a cold chamber machine does not have a gooseneck or
nozzle, and therefore aligns directly from the shot chamber.
Centrifugal casting or rotocasting is a casting technique that is
typically used to cast thin-walled cylinders. It is typically used to cast
materials such as metals, glass, and concrete. A high quality is
attainable by control of metallurgy and crystal structure.
Various types of centrifugal casting methods are in use. The main
principle behind any centrifugal casting is metal that is poured in to a
rotating mold exactly at center is thrown outward due to the action of
centrifugal force. The main advantage of centrifugal casting is the
impurities get accumulated exactly at the center.

Thetypesofcentrifugalcastingsare
1) True centrifugal casting
2) Semi centrifugal casting
3) Centrifuge casting
True centrifugal casting
This casting technique is employed when axis symmetrical objects
with uniform diameter are to be produced. Core is not employed in
these castings
working
A cylindrical mold is made to rotate about its axis at certain speed.
This speed is maintained in such a way that the metal which is
poured at the center is exactly thrown to the walls of the mold. In
this casting solidification starts from outside to inside. Wall
thickness of mold is regulated by amount of liquid that is being
poured. The impurities present in the molten metal due to its less
weight and can be machined easily. The molds of centrifugal casting
are made by metal (or) sand lined. The quality of mold depends on
the quality required.
Advantages of true centrifugal casting
1) Relatively very light impurities move inwards towards center. So they can be
removed easily thus helping in producing sound castings.
2) These castings have a directional solidification starting from outside to inside.
3) Central core is not required for making a hole or pipe
4) Employment of gates and risers is not required
5) This technique is best suited for the mass production of symmetrical objects.
6) Castings yield is very high in some cases it is even equal to 100%

Disadvantages of true centrifugal casting

1) Centrifugal castings require very high investments.
2) Skilled labors are to be employed for this process.
3) Only some shapes can be generated by this casting process.

Applications
1) Bearings for machines
2) Pipes
3) Liners for IC engines
4) Rings and other annular components
Semi-centrifugal casting
This is also similar to the true centrifugal casting but there is a
modification in it. These castings consist of a central core. Semi
centrifugal casting is employed for casting gear blanks, sheaves, and
wheels etc. low spinning speeds can be used speeds ranging
between 180 to 200 RPM is recommended. These castings are
normally prepared in vertical machines. The mold cavity is arranged
with in the mold so that its central axis is vertical and concentric
with the axis of rotation. Gating system is employed in the casting
for having a directional solidification.
Advantages
1) In this number of molds can be stacked together, one over the
other can be fed by a common central sprue in order to produce
more than one casting at a time.
2) Similar to true centrifugal casting it ensures purity and density of
the product poorer structure forms the center of the casting so this
can be machined off.
Centrifuge casting
This type of casting method is used for casting unsymmetrical castings in groups.
This is done in groups for obtaining balance of whole casting. In these castings the
axis of mold doesn't coincide with each other to induce the pressure on molds the
casting rotated at the center. Feeding to the mold cavities is done by central sprue by
the action of centrifugal forces. When castings are generated in multiple layers by
placing one over the other then it is called stack molding.
Advantages of centrifugal casting
1) Ensures better quality.
2) Castings when generated on large scale will be economical.
3) These castings generate high yield
4) The castings obtained by this method cannot be satisfactorily obtained by other
casting methods.
5) Cleaning and fettling cost of the castings can be reduced.
6) Denser castings having physical properties similar to those of forged products
7) Rejection percentage is very low
8) Easy way to achieve directional solidification
In investment casting, a wax or suitable polymer pattern is coated by
dipping into the refractory material slurry. Once the refractory
material coating is hardened then this dipping process is repeated
several times to increase the coating thickness and its strength. Once
the final coating is hardened the wax is melted out and molten metal
is poured into the cavity created by the wax pattern. Once the metal
solidifies within the mould, metal casting is removed by breaking the
refractory mould.
The first step involves creating the wax pattern that will eventually
be the final shape of the part(s). Wax is utilized because it is easily
melted and reused, but this also means that a wax pattern can only
be used once each time a part is made. This limitation requires the
manufacturer to have some sort of master mold, which can be
reused to create the wax patterns. These can be expensive because
they must be tailored to each part, and are tricky to perfect if
especially low tolerances are needed. However, if many of these
molds are made, they can be connected via a wax bar (known as a
“runner”) which allows for one pour to cast many parts. Finally, a
ceramic pouring cup (known as a “sprue”) is added to the top of the
wax pattern, so that manufacturers will have a funnel to pour the
molten metal into the final mold.
The second step in the investment casting process is when this
finalized wax pattern, complete with runners and sprues, is dipped
into a ceramic refractory slurry. This liquid usually contains
extremely fine silica, water, and other binders. When dipped, the part
will be covered in a thin layer of slurry, which is effectively a mold
of the wax pattern. This dipping step is done many times over to
achieve a certain coat thickness (often 5-10mm), and then the part is
dried. After drying, the part is turned upside down and heated to both
remove excess moisture and melt away the wax on the inside. Now,
manufacturers are left with a hollow ceramic mold of their desired
part.
The third step will occur right after the second, where manufacturers
will pour molten metal into the ceramic mold when it is still hot from
the drying/melting process. This pre-heating from the previous step
prevents the molten metal from damaging the ceramic mold, as well as
improves the flow of the metal into fine corners/detail areas. Also, as
the assembly cools down, both the ceramic mold and the metal will
shrink, providing better dimensional accuracy to the original wax
pattern. After the metal is cast, manufacturers wait for it to cool
completely.
The fourth and final step to investment casting is to break away the
ceramic mold when it is completely solid. This is often done with
water jets or other methods of removing the ceramic layer without
damaging the underlying metal. At this point, the finished parts are
ready to be cut from their runners and cleaned to their desired end
product finish.
Advantages
•Allows for the casting of highly complex, extremely accurate parts
with good surface finish right out of the mold.
•Can cast very thin sections with incredibly low tolerances .
Allows for the use of almost any metal capable of casting
(aluminum, bronze, iron, etc.)
•The investment casting process can be automated, generating a
huge amount of parts quickly
•The wax can be recovered and reused for many patterns
Disadvantages
Parts are best behaved in smaller sizes weighing up to around 75 lbs,
with large parts being generally better suited to other casting
processes
The process is complex and typically involves expensive equipment
and/or technicians to operate
The high cost of dies to make the wax patterns limits the processes to
high volume production projects
Parts with cores or holes smaller than 1.6 mm or holes deeper than
1.5 times the diameter of the part are difficult to investment cast
Shell molding, also known as shell-mold casting, is a process of
expendable mold casting using resin-covered sand to form the
mold. This method has greater dimensional precision, a greater
rate of productivity, and reduced employment costs relative to sand
casting. It is used for tiny to medium components that require high
precision.
Shell mold casting enables both ferrous and non-ferrous metals to
be used, most frequently using cast iron, coal steel, alloy steel,
stainless steel, aluminum alloys and metal alloys. Typical
components are small to medium in size and involve elevated
precision such as equipment housings, heads of the cylinder,
linking wires and arms of the lever.
The shell mold method comprises of six stages.
➢Fine silica sand coated in dense (3–6 percent) phenolic resin and
fluid catalyst thermosetting is poured, blown, or fired on a warm
model. Usually made of cast iron, the pattern is heated to 230 to 315
° C (450 to 600 ° F). For a few minutes, the sand is permitted to rest
on the structure to allow partial healing of the sand.
➢The pattern and sand are then reversed, leaving only the "shell"
free of the pattern. The shell size is 10 to 20 mm (0.4 to 0.8 in)
depending on the setup time and temperature.
➢Together the model and shell are put in an oven to complete the
sand healing. The shell now has a 350-450 psi (2.4-3.1 MPa) tensile
resistance.
➢Then the hardened shell is removed from the structure.
➢Using a thermoset adhesive, two or more shells are then combined
to form a mold by clamping or gluing. You can then use this
completed mold instantly or store it almost forever.
➢The shell mold is put inside a flask for painting and encircled by
shot, sand, or gravel to strengthen the shell.
Advantages of Shell Molding:
(1) Good dimensional tolerance of about + 0.2 mm is achieved.
(2) Good surface finish is generally obtained.
(3) This process itself suitable for automation.
Disadvantages of Shell Molding:
(1) The molding mixture contains thermosetting resin binders,
which are more expensive than other binders.
(2) Only suitable for metallic pattern and not for wooden or plastic
patterns.
(3) Cost of whole unit is high as compared to green sand moulding
method.
CO2 moulding is a special moulding process for making the
moulds and cores. The principle of this process is the chemical
action between sodium silicate and CO2 · Silica gel (SiO2 ·x·H2
O) is formed when CO2 reacts with sodium silicate. Hardening of
sand takes place which gives moulding strength to the mould
because of the silica gel that has been formed. The bonding
strength is sufficient to eliminate the drying or baking of the
mould. The chemical reaction between CO2 and sodium silicate is
given by:
Na2 O·m SiO2 ·x H2 O + CO2 → Na2 CO3 + m SiO2 · x H2 O
(silica gel)
The sand used for the process must be dry and free of clay. The
amount of sodium silicate to be mixed with the sand must be around
3 to 5 per cent. To enhance the collapsibility of the mould, coal
powder, wood flour and sea coal may be added as additives. Addition
of iron oxide prevents hot deformation of cores and produces smooth
interface between the mould and the metal. In this process CO2 gas is
passed through the mould for a predetermined length of time. The
amount of CO2 required can be calculated based on the sodium
solicate mixed with the sand. The flow rate of CO2 depends on the
depth of penetration desired.
Applications
1. Parts of valves, pumps and compressors.
2. Parts of machine tools, wheel castings, railway components.
3. Parts of diesel engines and gear castings.

Advantages
1. Labour cost and floor space are saved by avoiding drying or baking
of the mould.
2. High accuracy and good surface finish of the casting are possible.
3. Withdrawal of the pattern is facilitated since the moulds may be
hardened before extracting the pattern.
4. Mould cracking and deformation are prevented.
5. Process can be mechanized for mass production.
6. Less skill is required compared to dry sand moulding.
7. Machining allowances can be reduced.
Disadvantages
1. Moulds and cores are more expensive.
2. Difficult to reclaim the sand.
3. Life of the sand mixture is short.
4. Moulds and cores deteriorate if they are stored under normal
atmospheric conditions
Continuous Casting :
With the purpose of streamlining the production of metal slabs and
bars, the continuous casting process made the casting of metals like
brass, steel, aluminum, and copper much more efficient.
➢First, a steel ladle containing molten metal is titled in order to
pour the metal through a gas tight refractory tube into a container
called a tundish.
➢Next, holes at the bottom of the tundish allow molten metals to
flow into a series of copper molds at a controlled rate (Copper has
great thermal conductivity so it is able to cool the metals without
sticking to them).
➢Then, as the outer shell of the metals solidify, they are drawn
through water sprays and curved pipes to help them cool.
➢Finally, the metals emerge from the process as solid strands of
brass, copper, steel, Versa-bar cast iron or aluminum are cut into
manageable strands for further manipulation, storage, or shipment.
Advantages of Continuous Casting
Ability to cast regular shapes and certain irregular configurations in long
tubular form, which is difficult for other casting methods.
Continuous cast bars require appreciably less machining stock.
Continuous cast material is consistently dense and homogeneous in structure,
and therefore well-suited for pressure applications.
Straight, true, and concentric product for high speed bar machines.
Many suppliers maintain stock sizes for ready availability to distributors and
others requiring full lengths.
If the shape is optimized, the clean-up stock required on continuous cast
material is often less than that needed for parts produced with other casting
processes. Stock of 1/32 to 3/32 inches per side depending on the casting size
is normally adequate.
Continuous castings have an inherent advantage in mechanical properties over
other methods because of the chilling and the excellent feeding of molten
metal during solidification.
Continuous castings perform well under pressure.
Limitations or Things to Consider
Due to the considerable mold cost and casting machine set-up, it is
uneconomical to consider the continuous cast method for special
shapes or special alloys in small quantities. A customer may need to
order over 2,000 pounds of a special size or special alloy in order to
obtain a reasonable cost.
Thermocole (lost foam casting) pattern casting:
The lost foam casting process the lost foam casting process steps
1. Mold foam pattern sections.
2. Age pattern to allow dimensional shrinkage.
• The foam material used to create the pattern The foam material
used to create the pattern shrinks in much the same manner as a
typical shrinks in much the same manner as a typical casting.
casting.
• Patterns are “aged” by allowing them to rest at Patterns are
“aged” by allowing them to rest at room temperature for a period
of 5 to 7 days.
• Patterns may also be force aged in a drying oven Patterns may
also be force aged in a drying oven to allow for quicker use.
3. Assemble pattern if it is a multiple piece pattern.
• Production patterns are assembled using a assembled using a
automated precision, automated gluing machine.
• Glue is printed to one section of the foam and then pressed
against the adjoining piece.
• Multiple piece parts can be built up and produce very complex
geometry
4. Build cluster (multiple patterns per cluster).
• Glue individual patterns to sprue.
• Number of patterns per sprue is dependent on part size and/or
configuration.
• Molded sprue is manufactured similar to foam pattern
5. Coat cluster.
• Coating parameters are verified before coating cluster.
• Coating is mixed continuously to maintain properties.
• Cluster may be hand dipped or by automated robot station.
6. Dry coating.
• Coating is dried in an oven at 120 -140°F(49 - 60°C) for 3 to 5
hours.
7. Compact cluster in flask.
• Cluster is delivered to Cluster is delivered to the pouring line by
the pouring line by conveyor. conveyor.
• Cluster is placed into Cluster is placed into flask and held in
position flask and held in position by a fixture by a fixture
• Fixture is timed to Fixture is timed to release the cluster during
release the cluster during the compaction cycle. the compaction
cycle.
• Sand is rained into flask Sand is rained into flask from overhead
bin. from overhead bin.
• Compaction tables can be Compaction tables can be either
vertical or horizontal either vertical or horizontal in orientation
and vibrate in orientation and vibrate the flask during filling. the
flask during filling.
• Sand is compacted from Sand is compacted from approximately
90lb/ft³ to approximately 90lb/ft³ to 100 lb/ft³ by the 100 lb/ft³ by
the compaction table.
8. Pour metal.
• Metal is poured to Metal is poured to displace the polystyrene
displace the polystyrene pattern.
• Metal may be poured by Metal may be poured by hand or with
an hand or with an automatic ladle.
9. Extract cluster from flask.
• Casting is allowed to Casting is allowed to cool in sand for a
cool in sand for a predetermined period. predetermined period.
• Flask is then dumped Flask is then dumped on to a shakeout on
to a shakeout conveyor. conveyor.
• Loose sand around the Loose sand around the casting cluster
helps casting cluster helps protect the parts from protect the parts
from damage.
• Castings proceed through Castings proceed through shakeout to
remove loose shakeout to remove loose sand and coating sand
and coating.
Advantages/Disadvantages
There are many advantages to rapid prototype casting. There is a
reduced cost and lead time to create a part. There is little to no
machining needed and there is a high level of design freedom.
Incredibly complex shapes can be created with various characteristics
that are difficult to achieve with other methods. An example is parts
with thin walls. The finished metal parts have a nice surface finish. A
large disadvantage can be the time it takes to create a CAD design as
well as the level of expertise it requires. Part sizes are also limited to
the size of the printing area in the machine creating them. The metals
that finished parts can be created in is limited by metals with a lower
melting point.
Applications
Rapid prototype casting is used in a variety of industries including
the arts, computer technology, agriculture, national defense,
automotive, and hobby work. The type of parts that can be created is
wide, ranging from things like sculptural pieces, circuit boards, and
car parts.
Casting defects can be categorized into 5 types
1. Gas Porosity: Blowholes, open holes, pinholes
2. Shrinkage defects: shrinkage cavity
3. Mold material defects: Cut and washes, swell, drops, metal
penetration, rat tail
4. Pouring metal defects: Cold shut, misrun, slag inclusion
5. Metallurgical defects: Hot tears, hot spot.
Blow holes : When gases entrapped on the surface of the casting
due to solidifying metal, a rounded or oval cavity is formed called
as blowholes. These defects are always present in the cope part of
the mold.
Causes: 1.Excessive moisture content in molding sand. 2. Rust and
moisture on chills 3. Cores not sufficiently baked. 4. Excessive use
of organic binders. 5. Molds not adequately vented.
Remedies:1. Control of moisture content. 2. Use of rust free chills,
chaplet and clean inserts. 3. Bake cores properly. 4. Ram the
mold less hard.
Shrinkage : The formation of cavity in the casting due to volumetric
contraction is called as shrinkage cavity.
Causes: 1. Faulty gating and risering system.
2. Improper chilling.
Remedies: Ensure proper directional solidification by modifying
gating, risering and chilling.
Porosity : The definition of porosity is any void or hole in
a casting. ... Casting porosity can be caused by gas formation or
solidification shrinkage while the metal is a liquid. If a casting needs
to be pressure tight, then the porosity can allow gas and fluids to
seep from the part.
Causes: 1. High pouring temperatures. 2. Gas dissolved in metal
charge. 3. Less flux used. 4. Molten metal not properly degassed. 5.
Slow solidification of casting. 6. High moisture and low
permeability.
Remedies: 1. Regulate pouring temperature. 2. Control metal
composition. 3. Increase flux proportions. 4. Ensure effective
degassing. 5. Modify gating and risering.
Misruns: When the molten metal solidifies before completely filling
the mold cavity and leaves a space in the mold called as misrun.
Causes: 1.Lack of fluidity ill molten metal. 2. Faulty design.
3. Faulty gating.
Remedies: 1. Adjust proper pouring temperature. 2. Modify design.
3. Modify gating system
Hot Tears: when the metal is hot it is weak and the residual stress
(tensile) in the material cause the casting fails as the molten metal
cools down. The failure of casting in this case is looks like cracks
and called as hot tears or hot cracking.
Causes: 1. Lack of collapsibility of core. 2. Lack of collapsibility of
mold. 3. Faulty design.
4. Hard ramming of mold
Remedies: 1. Improves collapsibility of core and mold.
2. Modify casting design.
Metal penetration: These casting defects appear as an uneven and
rough surface of the casting. When the size of sand grains is larges,
the molten fuses into the sand and solidifies giving us metal
penetration defect.
Causes: 1. Large grain size and used. 2. Soft ramming of mold. 3.
Molding sand or core has low strength
Remedies: 1. Use sand having finer grain size. 2. Provide hard
ramming. 3. Suitably adjust pouring temperature.
Cold shuts: It is a type of surface defects and a line on the surface
can be seen. When the molten metal enters into the mold from two
gates and when these two streams of molten metal meet at a
junction with low temperatures than they do not fuse with each
other and solidifies creating a cold shut (appear as line on the
casting). It looks like a crack with round edge.
Causes: 1. Lack of fluidity in molten metal. 2. Faulty design.
3. Faulty gating
Remedies: 1. Adjust proper pouring metal. 2. Modify design.
3. Modify gating system.
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: 1. Low strength of mold and core. 2. Lack of binders in
facing and core stand. 3. Faulty gating.
Remedies: 1. Improve mold and core strength. 2. Add more binders
to facing and core sand. 3. Improve gating.
Inclusions : This defect is caused when the molten metal containing
slag particles is poured in the mold cavity and it gets solidifies.
Causes: 1.Faulty gating. 2. Faulty pouring. 3. Inferior molding or
core sand. 4. Soft ramming of mold. 5. Rough handling of mold
and core.
Remedies: 1. Modify gating system. 2. Improve pouring to minimize
turbulence. 3. Use of superior sand of good strength. 4. Provide
hard, ramming.
Fusion: Fusion occurs when sand grains fuse with molten metal. It
appears as a thin crust with a brittle, glassy appearance firmly
adhered to the casting.
Causes: 1. Low refractoriness in molding sand. 2. Faulty gating. 3.
Too high pouring temperature of the metal. 4. Pouring facing sand.
Remedies: 1. Improve refractoriness of sand. 2. Modify gating
system. 3. Use Lower pouring temperature. 4. Improve the quality of
facing sand.
Drops: Drop defect occurs when there is cracking on the upper
surface of the sand and sand pieces fall into the molten metal.
Causes: 1. Low green strength in molding sand and core. 2. Too
soft ramming. 3. Inadequate reinforcement of sand and core
projections.
Remedies: 1.Increase green strength of sand mold. 2. Provide
harder ramming. 3. Provide adequate reinforcement to sand
projection and cope by using nails and gaggers.
Shot metal : Cold shots
Splattering during pouring of a liquid can cause solid globules to
form. As these globules freeze, they become entrapped in
the casting. Cold shots are typically ball, drop or pearl shaped and
loosely attached to the metal.
Causes: 1. Too low pouring temperature. 2. Excess sulphur contests
in metal. 3. Faulty gating. 4. High moisture content in molding
sand
Remedies: 1. Use proper pouring temperature. 2. Reduce sulphur
content. 3. Modify gating of the system
Shift: The defect caused due to misalignment of upper and lower
part of the casting and misplacement of the core at parting line.
Causes: 1. Worn-out or bent clamping pins. 2. Misalignments of
two halves of pattern. 3. Improper support of core.
Remedies: 1.Repair or replace the pins, for removing the defect. 2.
Repair or replace dewels with cause misalignment. 3. Provide
adequate support to the core. 4. Increases strength of both mold and
core.
Swells: It is the enlargement of the mold cavity because of the
molten metal pressure, which results in localised or overall
enlargement of the casting.
Causes: Too soft ramming of mold. 2. Low strength of mold and
core. 3. Mold not properly supported
Remedies: 1.Provide hard ramming. 2. Increase the strength of both
mold and core.
Hard spot: Hot spot defects occur when an area on the casting cools
more rapidly than the surrounding materials. Hot spot are areas on
the casting which is harder than the surrounding area. It is also
called as hard spot.
Causes: 1. Faulty metal composition. 2. Faulty casting design.
Remedies: 1. Suitable charge metal composition. 2. Modify casting
design.
Run out, Fins and Fash : A thin projection of metal, not considered
as a part of casting is called as fins or fin. It is usually occurs at the
parting of the mold or core section.
Causes: 1.Faulty molding. 2. Defective molding boxes.
Remedies: 1. Improving molding techniques. 2. Change the defective
molding boxes. 3. Keep weights on mold boxes.