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21 Types Casting Defects
21 Types Casting Defects
21 Types Casting Defects
Gas porosity occurs when the metal traps gas (most often nitrogen, oxygen or hydrogen) during casting.
When the casting cools and solidifies, bubbles form because the solid form of the metal cannot hold as much
gas as the liquid form. These bubbles appear on a casting as rounded, circular cavities or holes.
1. Pinholes
Pinholes, also sometimes referred to as porosities, are very tiny holes (about 2 mm) usually found in the cope
(upper) part of the mold, in poorly vented pockets.
They usually appear in large numbers together, either at the surface or just below the surface of the casting.
They are always visible to the naked eye and don’t require equipment to identify.
2. Subsurface blowhole
Subsurface blowholes can be difficult to detect before machining, requiring harmonic, ultrasonic, magnetic or x-
ray analysis.
3. Open holes
These blowholes appear on the surface of the cast and are easier to detect than subsurface blowholes.
Scars are shallow blows that appear on a flat surface, while blisters are scars covered with a thin layer of
metal.
Dry out molds and cores before use and store dry
Shrinkage occurs because metals are less dense as a liquid than a solid.
A shrinkage cavity is a depression in a casting which occurs during the solidification process. Shrinkage porosity appears w
Large shrinkage cavities can undermine the integrity of the casting and may cause it to eventually break under
stress.
Shrinkage can result in two types of casting defects.
These are open to the atmosphere. Air compensated as the shrinkage cavity forms.
Pipes are open shrinkage defects that form at the surface and burrow into the casting. Caved surfaces are
shallow, open shrinkage defects that form across the surface of the casting.
Closed shrinkage defects usually appear at the top of hot spots, or isolated pools of hot liquid.
Prevent shrinkage cavities by improving casting structure
Alloys always shrink when changing from molten to solid. This is because the density of a casting alloy in the
molten state is lower than that in the solid state.
You should expect some shrinkage during solidification. Factor a shrinkage allowance into the pattern design before castin
You can prevent shrinkage casting defects by improving the overall casting structure:
Design a running (gate) system with risers that ensure a continuous flow of molten metal
Increase local heat dissipation by inserting internal chills, cooling ribs or cooling coils
A cut appears as a low projection along the surface of the drag face, decreasing in height as it extends from one
side of the casting to the other.
Causes and prevention of cuts and washes
Cuts and washes can be caused by molten metal flowing at a high velocity, causing too much metal to flow through the ga
7. Fusion
Fusion occurs when sand grains fuse with molten metal. It appears as a thin crust with a brittle, glassy
appearance firmly adhered to the casting.
Refractoriness is the ability of the molding material to resist the temperature of the liquid so it doesn’t fuse with
the metal. Silica sand has the highest refractoriness.
Improving the refractoriness of the molding material and/or reducing the pouring temperature of the molten
metal will help prevent fusion.
8. Run out
Run out is when liquid metal leaks out of the mold, leading to an incomplete or missing casting.
To prevent this casting defect, design the casting mold with precision. Inspect and replace any defective molds
before casting.
High temperatures can lead to excess wear and tear of the mold. Use quality raw materials for your mold that
can resist high temperatures.
9. Swells
Swells are an enlargement of the casting. Swells typically take on the shape of a slight, smooth bulge on the vertical face o
Causes and prevention of swells
Swell is usually caused by improper or soft ramming of the mold or a low strength mold.
Molds should be built to withstand liquid metal pressure. Otherwise, the mold wall may give way or move back,
causing swelling.
Drops occur when pieces of sand fall into metal casting when it’s still liquid. Drops appear as an irregularly
shaped projection on the cope (top) surface of a casting.
Insufficient fluxing of molten metal: Properly fluxing molten metal removes impurities
Insufficient reinforcement of sand projections in the cope: Reinforce sand projections using nails or
gaggers to fix this issue
Use of large or coarse sand grain: the coarser the sand grains, the more severe the metal penetration
You can typically remove metal penetration by grinding down the rough surface of the casting.
Metallurgical casting defects and causes
Some cracks are obvious and easily seen, while others can require magnification.
Hot tears are mostly caused by poor mold design. Modifying the mold to improve collapsibility can easily resolve
these issues.
Cold shut is a type of surface defect. You’ll see a line or crack with a round edge on the casting surface.
This defect is visible to the naked eye and often results in rejecting the cast, as it creates a weak spot.
When molten metal enters the mold from two gates, the streams will meet at a junction.
Low temperatures can prevent fusion at the junction, causing the streams to solidify before fusion, creating a
cold shut.
Cold shut is usually a result of a lack of fluidity of the molten metal, or a poor design of the gating system.
The best way to prevent cold shuts is to increase fluidity of the molten metal. This can be done in a few ways:
Optimize gating system to minimize narrow cross-paths and ensure short flow paths
Misruns occur when the liquid metal is too cold to flow to the extremities of the mold cavity before freezing and
solidifying.
The liquid metal does not completely fill the mold cavity. The misrun is the unfilled portion or space in the mold.
The reasons for premature solidification are similar to those for cold shut. If you have a misrun, check:
Mold design
Cold shots are typically ball, drop or pearl shaped and loosely attached to the metal.
Causes and prevention of cold shots
These irregular metallic crusts are found on the casting surface. Scabs are typically only a few millimeters thick
but can be seen by the naked eye. They usually have sharp edges, irregular shapes and are firmly bonded to
the casting.
Scabs are closely related to rat tails and they usually appear together. Removal of scabs will typically reveal a
rat tail underneath.
Slag inclusion is caused when molten metal containing slag particles is poured into the mold cavities and
solidifies.
Preventing slag inclusion is a simple fix. Remove slag particles from the molten metal before pouring it into the
mold cavity.
These types of casting defects are related to the overall shape of the final casting.
19. Shift/mismatch
Mold shift is due to misalignment of upper (cope) and lower (drag) part of the mold. Mold shift is usually
reflected as a horizontal displacement.
Core shift is similar to mold shift, but it’s the core that is misaligned, not the mold. Core shift is usually reflected as a vertic
Causes and prevention of shift
Flash is one of the most frequently occurring casting defects and also a common injection molding defect.
Flash, also known as casting fin or burrs, is any unwanted and excess material attached to a cast. It’s typically a thin sheet
Remedy this issue by reassembling the mold and cores. There should be enough weight on the top part of the
mold so that the two parts fit together tightly.
Flash can vary from minor to very serious. If it’s not too serious, manufacturers can remove flash by breaking it
off with a hammer or pliers and filing it down to the parting line. However, this can be a costly process.
21. Warping
Warping is an unwanted casting deformity that can occur over time, which results in a change in the dimensions
of the final product.It can happen during or after solidification.
Normalizing heat treatment can remove residual stress in iron casting. A straightening between quench and
aging processes might also be required for aluminum casting.
Conclusion
You should set clear defect tolerances and quality expectations with your suppliers before production to help
them understand your quality standards.
Defect tolerance can vary between products and types of casting defects. Determining your tolerance for these
casting defects can help your supplier better understand your standards and prevent future misunderstandings
and quality issues.
Ultimately, the manufacturer must strictly control quality of each casting process. Experienced importers rely on quality co