International Journal of Design and Manufacturing Technology (IJDMT)

Volume 7, Issue 1, January-April 2016, pp. 60–62, Article ID: IJDMT_07_01_006

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CASTING DEFECTS: AN LITERATURE

REVIEW
Vasdev Malhotra
Associate Professor, Mechanical Engineering Department,
Mechanical Engg., YMCAUST, Faridabad -121006, India

Yogesh Kumar
M.Tech Student, Mechanical Engineering Department,
YMCAUST, Faridabad -121006, India

ABSTRACT
Casting process is associated with some casting defects that degrade the
quality of foundry product. To upgrade the productivity of the organization the
casting defects should be minimized. This paper shows the different literature
review and root causes of casting defects taken by the different foundry
expert’s.
Key words: Casting, foundry, productivity, Defects
Cite this Article: Vasdev Malhotra and Yogesh Kumar, Casting Defects: An
Literature Review. International Journal of Design and Manufacturing
Technology 7(1), 2016, pp. 60–62.
http://www.iaeme.com/IJDMT/issues.asp?JType=IJDMT&VType=7&IType=1

1. INTRODUCTION
In today’s developing world, extent of automation is increasing with a rapid rate day
by day. In this race one important thing which was always neglected was to introduce
human thinking capability in machines. But now a day this technology is paid
attention to a quite larger extent. Concepts of artificial intelligence have a very wide
application now a day especially in terms of daily life [5]. A defect may arise due to a
single cause or may be due to presence of some more causes it depends on foundry
shop and its resources available. The defect occurred in casting are generally very
intuitive in nature because the root cause is not particularly identified by the foundry
men but if a deep scrutiny of defects is done then you may be able to relate the casting
defects with the input variants which can be changed considerably. In order to
determine the parameters that affect the formation of porosity and shrinkage defects in
castings, a number of discussions were made with concerned technicians in the
manual as well as mechanized molding. The probable causes suggested by the the
experts of the foundry as below

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 Casting Defects: An Literature Review

 Mould moisture content

 Pouring velocity
 Pouring time
 Solidification time
 Gate and runner and riser design
 Mould permeability
 Sand binder ratio
 Poor venting

2. LITERATURE REVIEW
The different literature review regarding the casting defects as below:
2.1 M. Dussud et, al , 1996, has done a research on minimisation of casting defects
by analysing the root causes of some casting defects in ABMI industries.In this paper
the statistical analysis is aimed to optimize process parameters at the case study, i.e.
Akaki Basic Metals Industry (ABMI) in Addis Ababa Ethiopia, to minimize major
steel casting defects. This project is intended to observe just two of the steel casting
defects which are severe in their nature i.e., gas defects and shrinkage defects. In
order to obtain a representative experimental data it was used a factorial experiment..
The relative influence of each factor on the casting defect/porosity/ was determined
and suggestions have been given by using the Statistical Analysis method by
optimizing the process parameters.
2.2. Adil Mohamed et , al 2011, have done research on feeder design for casting. In
this paper, a feature-based solid modeling integrated with a fuzzy expert system was
developed. The feature-based model had been developed by the authors, to provide
manufacturing information to the fuzzy system application. The fuzzy system is based
on heuristic rules of feeder in paper, to classify castings and design feeders. Heuristic
rules were encoded inside the fuzzy system in production rules: IF-THEN-ELSE. The
fuzzy system was connected with the model through open database connectivity
database. Results inferred from fuzzification of inputs and defuzzification of outputs
through inference process. A design condition flow chart was built to evaluate the
results.[2]
2.3. B. Kalandyk et , al 2009, have done a research on continuous casting process in
which product usually got cracked due to internal structure, but these researchers has
developed a mechanism to reduce or mitigate these defects by using two fuzzy
controllers. In the process of continuous casting, the melted steel from the melting pot
is passed through the intermediary of the distributor, in the water-cooled crystallizer
tank. In this way, a crust forms here which is solidified at the exterior, and one of the
great problems is its cracking or even it’s tearing, due to several factors. This paper
describes a new control method we should use during the continuous casting. This
method is based on the fuzzy logic, in order to avoid any crack inside the crystallizing
apparatus. This method contains two fuzzy controllers which, based on a set of rules
and these rules frame a rule base which is based upon certain reasoning implications.
2.4. K. Omura et al , 1990. deals with the problem of molten metal level control in
continuous casting. Under normal circumstances, proportional integral derivative
(PID) control performs quite well, but abnormal conditions (in particular nozzle
clogging/unclogging) require manual intervention. Indeed, when the flow of matter
into the mold increases suddenly, the PID controller is not always able to prevent

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 Vasdev Malhotra and Yogesh Kumar

large level variations that can even lead to mold overflow. So, a fuzzy controller has
been designed using the expert knowledge of the operators for controlling the process
during disturbed phases. The paper discusses both the design of the fuzzy logic
controller and its integration with the PID in a global control architecture.
2.5 Rajesh Rajkolhe, J. G. Khan ( 2014), has conducted a thorough study of casting
defects and their remedies.Foundry industries in developing countries suffer from
poor quality and productivity due to involvement of number of process parameter.
Even in completely controlled process, defect in casting are observed and hence
casting process is also known as process of uncertainty which challenges explanation
about the cause of casting defects. In order to identify the casting defect and problem
related to casting, the study is aimed in the research work. This will be beneficial in
enhancing the yield of casting. This study aims to finding different defects in casting,
analysis of defect and providing their remedies with their causes. In this paper an
attempt has been made to list different types of casting defects and their root causes of
occurrence. This paper also aims to provide correct guideline to quality control
department to find casting defects and will help them to analyze defects which are not
desired.

3. CONCLUSION
Casting defects are very serious for the industry. These defects should be minimized.
In this paper the different review of researchers have discussed regarding the casting
defects.

REFERENCES
[1] M. Dussud, S. Galichet, L. Foulloy, and P. Simonnin, “Fuzzy logic control
of continuous casting installations,” in Proc. 13th IFAC World Congr., San
Fransisco, CA, 1996, vol. M, pp. 469–474.
[2] Adil Mohamed Elbasheer Ahmed, Mohamed Ibrahim Shukri,
WaielFathiAbd El-Wahed, “A Fuzzy Expert System for Rigging System
Design”Journal of Science and Technology 12 (02 ) December 2011 ISSN
1605 – 427X
[3] Rajesh Rajkolhe, J. G. Khan, “casting defects and its remedies” published
in “International Journal of Research in Advent Technology”, Vol.2, No.3,
March 2014 E-ISSN: 2321-9637
[4] Er. NavjotKaur, Er. Navleen Singh Rekhi, AnandNayyarM. Dussud, S.
Galichet, L. Foulloy, and P. Simonnin, “Fuzzy logic control of,“Review of
Expert Systems based on Fuzzy logic” in “International Journal of
Advanced Research in Computer and Communication Engineering” Vol.
2, Issue 3, March 2013
[5] K. Omura, Y. Otsuka, and M. Konishi, “Diagnostic expert system for mold
level control equipment in continuous caster,” in Proc. 6th Int. Iron and
Steel Congr., Nagoya, Japan, 1990, pp. 62–68.
[6] B. Kalandyk, R. Zapała, A. Rakowska, Characteristics of defects present in
industrial steel castings due to metal-mould reactions, Archives of
Metallurgy and Materials 54, 2 (2009).

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