Experiment No.

8
Casting Defects

Aim: To study and understand different casting defects and their causes.

Theory:
A casting defect is an irregularity in the metal casting produced and is undesired. Casting defects
may be defined as those characteristics that create deficiency or imperfection contrary to quality
specifications and requirements. Some defects can be tolerated while others can be repaired
otherwise they must be eliminated. Accordingly they are classified as:

a) Major Defects-Defects cannot be rectified and the casting is to be rejected

b) Defects that can be remedied or repaired but the cost of repairing is high
c) Minor Defects-Defects that are allowed and can be repaired at low cost
The approach of elimination is dependent on the cost and economics.
The general origins of defects may lie in sectors like casting design, manufacturing technique,
workmanship etc. The cause of defect may be singly defined or may be a combination of many
factors. Thus control over process and fundamental understanding of causes of defects becomes
very important to maintain the defect level to the minimum.

Types of Casting Defects:

Following are the major defects that usually occur in sand castings:

1. Gas porosity defects:

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. Gas porosity may present itself on the surface of the casting as porosity or the pore
may be trapped inside the metal, which reduces strength in that vicinity.
 Causes -lower permeability, improper running and feeding system, oxidized metal
or dissolved gases.
 Remedies- Proper risering, degassed metal pouring, proper venting etc.

2. Pouring Metal Defects

 The defects occurring in this category are Mis-runs and cold-shuts.
A mis-run is caused when the metal is unable to fill the mold cavity completely
and thus leaves unfilled cavities. A mis-run results when the metal is too cold to
flow to the extremities of the mold cavity before freezing.  Long, thin sections are
 subject to this defect and should be avoided in casting design.
A cold shut is caused when two streams while meeting in the mold cavity, do not
fuse together properly thus forming a discontinuity in the casting. When the
molten metal is poured into the mold cavity through more-than-one gate, multiple
liquid fronts will have to flow together and become one solid.  If the flowing
metal fronts are too cool, they may not flow together, but will leave a seam in the
part.  Such a seam is called a cold shut.
 Causes- lower fluidity of the mold, lower pouring temperature, small section
thickness, multiple gate pouring.
 Remedies- sufficient superheating, lower degree of ramming.

3. Metallurgical Defects
Hot Cracking is typical example in this category.
 Causes-Internal residual stresses(opening up during cooling)
 Remedies-Proper design

4. Shrinkage and draws

It appears as rough cavities or depressions on casting surface .High pouring temperatures
of metal may result in shrinkage. Directional solidification is useful in avoiding it.
 Causes- Improper gating system, Unsuitable metal composition.
 Remedies-Efficient riser system, Cushioners like saw- dust.

5. Scabs
Scabs are like projections on casting that occur when part of mould face lifts and metal
flows beneath in a thin layer. They appear as rough excretions on surface of castings.
Scabs are of two types-expansion and erosion scabs. Expansion scabs occur when surface
layers of mould expand. Erosion scabs occur when metal is agitated or has partly eroded
sand.
 Causes-uneven ramming, sand grains not uniform, excess moisture, weak sand
bonding.
 Remedies-use Cushioners, avoid uneven and hard ramming, reduce moisture.

6. Mismatch and Distortion

Mismatch usually occurs at parting line and is easy to identify. It occurs when cope and
drag boxes are not aligned properly.
Distortion in casting is observed as swelling on the surface of casting. It occurs because
of uneven mould hardness.
 Causes-Misalignment of cope and drag boxes, improper moulding methods.
 Remedies-Proper markings and design, Appropriate method of moulding.
7. Cracks
Two types-Hot crack and cold crack.
Appears as hairline cracks on casting.
 Causes-high dry strength. Hard cores. mechanical damage.
 Remedies-lower oil content in cores, Proper breaking of risers and gating system.
 8. Slag holes
Appear as smooth depressions or cavities on surface of casting
 Causes-Improper gating system, Poor fluxing of metals
 Remedies-low impurity content in molten metal, Proper pre-treatment of metal.

Defect Analysis and Inspection:

Defect analysis is important and required to understand the reasons of defects and accordingly
modify the parameters and casting system. Inspection of defective castings is done to ensure the
good quality of castings produced. Methods like- visual inspection, dimensional inspection,
mechanical and chemical inspection, metallurgical inspection etc. are usually employed to check
the quality and flaws in castings.

Conclusion:
The significance and repairing of casting defects needs to be decided on their function
(application) and cost economics. Behaviour of castings under service condition depend on how
defects influence their mechanical properties, surface finish, soundness etc.
Casting Defects:

Defect Type Image/Sample picture

Gas porosities

Pouring Metal defects

Metal Shrinkage

Scabs(Rat-tails)
Mis-match and Shift

Metal penetration

Blow Hole

Inclusion in castings