Scribd
Upload
123 views

Casting Defects

Uploaded by

Arbaz Jutt
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
123 views

Casting Defects

Uploaded by

Arbaz Jutt
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 24

Casting defects

Definition
• A casting defect is an undesired irregularity in
a metal casting process.
Types of casting defects
Types of casting defects
1. Shrinkage defects
2. Gas porosity
3. Pouring metal defects
4. Metallurgical defects
1. Shrinkage defects
• This defect occurred when extra metal is not
available to compensate for metal shrinkage

• Open shrinkage defect (located outside the


casting)
• Closed shrinkage defect (located inside the
casting)
Open and close shrinkage defects
How to overcome?
• By the use of riser
• By making the pattern usually of larger size as
compared to the original product
2. Gas porosity
• Gas porosity is the formation of bubbles
within the casting after it has cooled. This
occurs because most liquid materials can hold
a large amount of dissolved gas, but the solid
form of the same material cannot, so the gas
forms bubbles within the material as it cools.
2. Gas porosity
• Nitrogen, oxygen and hydrogen are the most
encountered gases in cases of gas porosity.
2. Gas porosity
2. Gas porosity
2. Gas porosity
• Tiny gas bubbles are called porosities, but
larger gas bubbles are called blowholes or
blisters. Such defects can be caused by air
entrained in the melt, steam or smoke from
the casting sand, or other gasses from the
melt or mould.
2. Gas porosity
• Proper foundry practices, including melt
preparation and mould design, can reduce the
occurrence of these defects. Because they are
often surrounded by a skin of sound metal,
blowholes may be difficult to detect, requiring
harmonic, ultrasonic, magnetic, or X-ray (i.e.,
industrial CT scanning) analysis.
3. Pouring metal defects
• Pouring metal defects include misruns, cold shuts,
and inclusions.
• A misrun occurs when the liquid metal does not
completely fill the mould cavity, leaving an unfilled
portion.
• Cold shuts occur when two fronts of liquid metal do
not fuse properly in the mould cavity, leaving a weak
spot. Both are caused by either a lack of fluidity in
the molten metal or cross-sections that are too
narrow
3. Pouring metal defects
• Misruns and cold shuts are closely related and
both involve the material freezing before it
completely fills the mould cavity. These types
of defects are serious because the area
surrounding the defect is significantly weaker
than required
3. Pouring metal defects
• An inclusion is a metal contamination of
dross, if solid, or slag, if liquid. These usually
are impurities in the pour metal (generally
oxides, less frequently nitrides, carbides, or
sulfides), material that is eroded from furnace
or ladle linings, or contaminates from the
mould.
3. Pouring metal defects (misrun)
3. Pouring metal defects (coldshut)
3. Pouring metal defects (inclusion)
4. Metallurgical defects
• There are two defects in this category: hot
tears and hot spots.
• Hot tears, also known as hot cracking, are
failures in the casting that occur as the casting
cools. This happens because the metal is weak
when it is hot and the residual stresses in the
material can cause the casting to fail as it
cools. Proper mould design prevents this type
of defect.
4. Metallurgical defects
• Hot spots are sections of casting which have
cooled down more slowly than the
surrounding material due to higher volume
than its surrounding. This causes abnormal
shrinkage in this region, which can lead to
porosity and cracks. This type of defect can be
avoided by proper cooling practices or by
changing the chemical composition of the
metal
Summary of defects
Defects related to die casting process

• In die casting the most common defects are


misruns and cold shuts. These defects can be
caused by cold dies, low metal temperature,
dirty metal, lack of venting, or too much
lubricant. Other possible defects are gas
porosity, shrinkage porosity, hot tears, and
flow marks. Flow marks are marks left on the
surface of the casting due to poor gating,
sharp corners, or excessive lubricant
Defects related to die casting process

You might also like