Pouring molten metal into a mold shaped

after the part to be produced (mold cavity),

allowing it to harden, and removing it from
the mold.
Can be used to create complex internal
and external part geometries
Some casting processes can produce parts
to net shape (no further manufacturing
operations are required i.e precision
casting)
Can produce very large parts (cast parts
weighing over 100 tons have been made)
Can be used with any metal that can be
heated to its liquid phase
Requirements:
Mold cavity with desired shape and size
Melting process to provide molten metal
Pouring process to introduce the metal
into the mold
Solidification process controlled to
prevent defects
Ability to remove the casting from the
mold
Cleaning, finishing and inspection
operations
 Casting process is also known as process of
uncertainty. Even in a completely controlled
process, defects in casting are found.
 The cause of defects is often a combination of
several factors rather than a single one. When
these various factors are combined, the root
cause of a casting defect can actually become a
mystery. It is important to correctly identify the
defect symptoms prior to assigning the cause to
the problem. False remedies not only fail to
solve the problem, they can confuse the issues
and make it more difficult to cure the defect.
The proper classification and identification of a
particular defect is the basic need to correct and
control the quality of casting.
01. Shrinkage
02. Cold Shut
03. Mismatch
04. Blow holes
05. Pin Holes
06. Fin
07. Drop
08. Swell
09. Metal Penetration
10. Hot Tears
11. Porosity
12. Scabs
13. Hard Spots
14. Buckles\Rat Tails
15. Misrun
Shrinkage cavity is a void on the surface of the
casting caused mainly by uncontrolled and
haphazard solidification of the metal.
Causes:
 inadequate and improper gating
 poor design of casting involving abrupt
changes in thickness
 too high pouring temperature
Remedies:
 Use the suitable mold design and gating
system
 Carry out proper ramming and maintain
optimum pouring temperature and time.
When two streams of molten metal approach each
other in the mould cavity from opposite directions
but fail to fuse properly, with the result of
discontinuity between them, it is called a cold
shut.
Causes:
 low temperature of molten metal
 improper gating system
 too thin casting sections
 slow and intermitted pouring
 improper alloy composition
 use of damaged pattern

Remedies:
 Smooth pouring with the help of monorail.
 Properly transport mould during pouring.
 Arrange proper clamping arrangement.
 providing appropriate pouring temperature
It is a shift /misalignment between two mating
surfaces or the top and bottom parts of the
casting at the mould joint.
Causes:
 worn dowel in patterns made in halves.
 improper alignment of mould boxes due to
worn out/ill fitting mould boxes.
Remedies:
 Properly arrange box warpage.
 Properly move boxes with pins.
 Properly clamp the boxes.
Balloon-shaped gas cavities caused by release
of mould gases during pouring are known as
blow holes.
Causes:
 ramming is too hard.
 permeability is insufficient.
 venting is insufficient.

Remedies:
 moisture content of moulding sand should be
controlled
 sand of appropriate grain size should be
used.
 ramming should not be too hard.
 moulds should be adequately vented.
Pin holes are tiny blow holes appearing just
below the casting surface.
Causes:
 sand with high moisture content.
 absorption of hydrogen/carbon monoxide gas in the
metal.
 alloy not being properly degassed.
 steel is poured from wet ladles.
 sand containing gas producing ingredients.

Remedies:
 reducing the moisture content of moulding sand.
 increasing its permeability.
 employing good melting and fluxing practices.
 improving a rapid rate of solidification.
Fins are excessive amounts of metal created by
solidification into the parting line of the
mold
Causes:
 inadequately weighted sand as well as
incorrectly assembled moulds and cores.
 over flexible bottom boards.
 loose plates and improper clamping of flasks.

Remedies:
 correctassembly of the mould and cores
used for casting.
Drop is an irregularly-shaped projection on the
cope surface caused by dropping of sand.
Causes:
 low green strength of the moulding sand.
 low mould hardness.
 insufficient reinforcement of sand
projections in the cope.
Remedies:
 moulding sand should have sufficient green
strength.
 ramming should not be too soft.
Swells are excessive amounts of metal in the
vicinity of gates or beneath the sprue
Causes:
 insufficient
or soft ramming.
 low mould strength.
 mould not being adequately supported.

Remedies:
 sand should be rammed evenly and properly.
Penetration occurs when the molten metal flows
between the sand particles in the mould. These
defects are due to inadequate strength of the
mold and high temperature of the molten metal
adds on it.
Causes:
 low strength of moulding sand.
 large size of moulding sand.
 high permeability of sand.
 soft ramming.

Remedies:
 useof fine grain with low permeability.
 appropriate ramming.
A hot tear is a fracture formed during
solidification because of hindered contraction.
Causes:
 faulty casting design leading to excessive stresses
at certain portions in the casting.
 very hard ramming.
 too much shrinkage of molten metal.
 incorrect pouring temperature.
 improper gates and risers.
 low flowability of molten metal.
 high sulphur content in molten metal.
Remedies:
 ramming should not be too hard.
 modification in pattern to take care of residual
stresses.
Porosity is pockets of gas inside the metal
caused by micro-shrinkage during
solidification.
Causes:
 dissolved hydrogen and sulphur dioxide in molten
metal.
 excessive poring temperature.
 slow rate of solidification.
 high moisture content of the mould.

Remedies:
 maintenance of proper melting temperature.
 casting should be made to solidify quickly by using
proper gating and risering.
 permeability of the mould should be increased.
 moisture content of mould should be kept low.
Scabs are surface slivers caused by splashing and
rapid solidification of the metal when it is first
poured and strikes the mold wall
Causes:
 insufficient strength of mould and core.
 uneven mould ramming.
 lack of binding material in facing as well as core
sand.
 Faulty gating.
 intense local heating due to slow running of
molten metal over sand surface.
Remedies:
 appropriate ramming.
 improved gating system.
 addition of sufficient binders in facing and core
sands.
These spots are formed due to the local chilling by
moulding sand which leads to the formation of
white cast iron at those places, rendering them
hard.
Causes:
 faulty metal composition.
 faulty casting design resulting in relatively
more rapid cooling of certain spots.
Remedies:
 modification of casting design.
 modification of casting composition.
Rat tail or a buckle is a long, shallow, angular
depression caused by expansion of the sand.
Causes:
 excessive mould hardness.
 lack of combustible additives in the moulding
sand.
 continuous large surfaces on the casting.

Remedies:
 suitableaddition of combustible additives to
moulding sand.
 reduction in mould hardness.
 modifications in casting design.
When the molten metal fails to fill the entire
mould cavity before the metal starts solidifying
, resulting in an incomplete casting, the defect
is known as misrun.
Causes:
 low temperature of molten metal
 improper gating system
 too thin casting sections
 slow and intermitted pouring
 improper alloy composition
 use of damaged pattern
Remedies:
 Smooth pouring with the help of monorail.
 Properly transport mould during pouring.
 Arrange proper clamping arrangement.
 providing appropriate pouring temperature.