Analysis of casting defects at tkt high-tech cast pvt. ltd.

ANALYSIS OF CASTING DEFECTS AT TKT

HIGHTECH CAST PVT. LTD.
By
THAKER YASH P.
SHAH ABHISHEK S.
VYAS MAHARSHI J.
PATEL RAKESH J.

Under the Guidance of

Mr. Kunal B. Thakkar
Director
TKT High-tech cast pvt. ltd.
A Report Submitted to
TKT High-tech cast pvt. ltd.
Nov-Dec 2015

M/S TKT high-tech cast pvt. ltd.

Plot No.6 Survey No. 254/1, Opp. Chharodi Railway station, SanandViramgam highway Taluka-Sanand Dist- Ahmedabad Pin-382170

Analysis of casting defects at tkt high-tech cast pvt. ltd.

ABSTRACT
In the foundry and casting industries there are so many interception
they have to face. The main crux they are facing is casting defects. Due to
the casting defects the rejection rate of the manufacturing batch is raise
which drag the organization to the detriment. The losses perhaps harm the
firm abundant, like deterioration of the raw material, the wastage of time
and manpower too. The rejected products due to casting defects may
restrain the additional space in organization and also take some excerpt
manpower to handle the scrap due to the casting defects. It also leads to
delay the dispatching process. In conclusion the casting defects engender
contrariness for avocation of organization.
Therefore, here first of all we are finding the casting defects in our
current working industry TKT HIGHTECH CAST PVT. LTD. And we
enquiring the difficulties of casting defects and the type of casting defects
which are the industry facing presently.

Analysis of casting defects at tkt high-tech cast pvt. ltd.

LIST OF DEFECTS
01. Ingate Shrinkage
02. Sand fusion
03. Mismatch
04. Cold shut or cold lap
05. Blow holes
06. Core tilting or core shift
07. Slag Defect
08. Scabbing

Analysis of casting defects at tkt high-tech cast pvt. ltd.

1. Ingate Shrinkage

Fig :- Ingate Shrinkage

Possible causes
The density of a die casting alloy in the molten state is less than its
density in the solid state. Therefore, when an alloy changes phase
from the molten state to the solid state, it always shrinks in size.
This shrinkage takes place when the casting is solidifying inside a
die casting die. At the centre of thick sections of a casting, this
shrinkage can end up as many small voids known as shrinkage
porosity.
If the shrinkage porosity is small in diameter and confined to the
very centre of thick sections it will usually cause no problems.
However, if it is larger in size, or joined together, it can severely
weaken a casting. It is also a particular problem for castings which
need to be gas tight or watertight.
Using too thin sprue can also cause the shrinkage defect.
Proposed Solution
Slight modification in design, using slightly thick sprue can
minimize this defect.

Analysis of casting defects at tkt high-tech cast pvt. ltd.

2. Sand fusion

Fig:-Sand fusion

Possible causes

Clay-bonded sand
Lustrous carbon content too low
Proportion of low-melting-point substances too high
Moulding plant
Uneven mould compaction
Gating and pouring practice
Uneven distribution of inflowing metal with resultant over-heating
Temperature of liquid metal too high

2.3 Proposed solution

Mould compaction should be even so that it doesnt
loose its porosity after loading.
Make sure proportion of water content in mould making is
maintained

Analysis of casting defects at tkt high-tech cast pvt. ltd.

3. Mismatch defect

Fig:-Mismatch
Possible causes
A mismatch is caused by the cope and drag parts of the mould not
remaining in their proper position.
This is caused by loose box pins, inaccurate pattern dowel pins or
carelessness in placing the cope on the drag.
Proposed solution
Make sure cope and drag part match properly in molding machine
Loose patent pins should be checked regularly

Analysis of casting defects at tkt high-tech cast pvt. ltd.

4. Cold lap or cold shut

Fig:- cold lap or cold shut

Possible Causes
Lack of fluidity in molten metal
Faulty design
Faulty gating
High moisture content in mold sand

Proposed solution
Maintain pouring time.
Maintain pouring temperature.
Make sure not to use damaged patent.

Analysis of casting defects at tkt high-tech cast pvt. ltd.

5. Blowhole

Fig:-Blowhole

Possible causes
Inadequate core venting
Excessive release of gas from core
Excessive moisture absorption by the cores
Low gas permeability of the core sand
Clay-bonded sand
Moisture content of sand too high, or water released too quickly
Gas permeability of the sand too low
Sand temperature too high
Bentonite content too high
Too much gas released from lustrous carbon producer.
Resin-bonded sand

Proposed solution
Bentonite content should be maintained
Use sand with high gas permeability
Make sure moisture content in sand is not too high

Analysis of casting defects at tkt high-tech cast pvt. ltd.

6. Core tilting or core shift

Fig:-Core tilting or Core shift

Possible causes
Improper core sitting.
Improper flow of molten metal while pouring.
Using damaged cores.

Proposed solution
Do not use damaged cores.
Make sure core sit is proper in mould

Analysis of casting defects at tkt high-tech cast pvt. ltd.

7. Slag Defect

Fig:-Slag Defect

Possible causes
Oxide content of the charge too high
High impurity levels of oxides and hydroxides in charge materials
Poor or slow dissolution of inoculants
Ladle lining too highly reactive
Poor deslagging of the molten metal

Proposed solution
Remove slag as much as possible at the time of melting.
make sure inoculants is dissolved completely and also maintain
amount of inoculant added per mould.

Analysis of casting defects at tkt high-tech cast pvt. ltd.

8. Scabbing

Fig:-Scabbing
Possible causes
Clay-bonded sand
Too little bentonite or poor bentonite quality in the moulding
sand
Proportion of fine quartz in the sand too high
Moulding sand too fine
Insufficient conditioning of bentonite
Too much salt in the sand
Gating and pouring practice
Sand heated up too severely by inflowing metal and long
exposure to radiated heat
Proposed solution
Maintain moisture content in moulding sand according to ambient
temperature.
Use proper amount of bentonite and also maintain quality of
bentonite.

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Analysis of casting defects at tkt high-tech cast pvt. ltd.

REFERECES
1. John Fernihough, Matthias Dr. Hoebel, Maxim Dr. Konter
Method Of Removing Casting Defects Application numberEP20020405142
2. Ernst wiss Remedying Defects, Such As Blow Holes In Metal
Castings Application number-US884,346
3. Susumu Ihara, Hiroyuki Yoshimoto, Katsumi Mizuuchi, Hideo
Nishiumi, Takanobu Suzuki Method And Apparatus For
Detecting Internal Cavities In Casting Bars Application numberUS 05/864,910
4. Joseph M.VihtelicInvestment Casting With Improved As-Cast
Surface Finish Application number- US08/736,534
5. Hansen Method and equipment for feeding shrinkage voids in
metal castings Patent number- EP0738192B1
6. Pradeep kumar Mould modification for eliminating freckle defects
in roll casting Patent number- US3882942
7. Rajesh Rajkohle, J.G. Khan; Defects, Causes and Their Remedies
in Casting Process, A Review, International Journal Of Research
In Advent Technology, Vol-2,no-3, March- 2014, page no:03-09.
8. V.V.Mane, Amit Sata and M. Y. Khire New Approach to Casting
Defects Classification and Analysis Supported by Simulation

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