COBALT CHROME 3

ADMISSION: BDT/2020/89365
NAME: MERCY WAMBUI
DATE OF SUBMISSION: 29TH MARCH 2023
CASTING DEFECTS

Definition: An unwelcome irregularity that develops in the casting during the metal casting
process is known as a casting flaw. The flaws in the cast metal can be attributed to a number of
causes or sources. Some manufacturing flaws can be disregarded or tolerated, but others must
be eliminated if we want the components to work better.

CLASSIFICATION OF CASTING DEFECT

Metallurgical defects:

 Porosity, sinks, inclusion, dross, soldering.

Defects due to heat:

 Hot tears, cold shut, thermal fatigue.

Mechanically induced defects:

 Surface marks, bending, undercuts

Types

 Gas porosities

Because cast metal can't contain as much gas as it can when it's liquid, it releases it as it
solidifies in the mold. Molds' ability to let gas out is one of the reasons they are porous.
Impermeability, which can lead to gas bubbles getting trapped inside the metal, can be brought
on by a number of variables. These BUBBLES could contain:

 Pin holes
Pin openings are smaller openings in the top of a casting that are also referred to as porosities.
They can be seen with the naked eye, typically in groups close to or at the casting's surface.

 Blowholes

Larger holes known as "blow holes" may develop inside a cast component. Interior blowholes
can be found using x-ray, harmonic, ultrasonic, or magnetic analysis but are invisible to the
unaided eye. Shallow, thinly covered openings are blisters, a variation of blowholes.

 Open holes

Open Holes: Blowholes, which are bigger holes, can develop inside a cast piece. Interior
blowholes, which are invisible to the unaided eye, can be found using x-ray, harmonic,
ultrasonic, or magnetic analysis. Blisters are a subtype of blowholes that are sparsely covered
and shallow.

1. Causes of gas porosity

 Speed of metal pouring is too slow .

 Presence of gas in metal.
 Mould is too hot.
 Presence of moisture in flux.
 Incomplete casting.
 Metal section is too thin.
 Overheated moulds.
 Temperature of pouring metal is low.

Remedies

 Metal is poured as quickly as feasible without any interaction

 Implement vacuum degassing. Vacuum-melt the metal.
  Maintain a moderate mold temperature.
 Utilize sufficient core and mold venting.
 Fill the mold with enough metal in the ladel.
 Boost the gate mechanism.
 Change the casting design to omit the thin metal portion and enhance the runner.
 Temperature increase for metal filling.

SHRINKAGE DEFECTS

Metal alloys contract as they cool, which causes shrinkage defects to emerge. As an alloy
component solidifies, it is typical for it to contract. (which should be included in calculations
when designing the mold). But when the metal shrinks unevenly, it produces flaws that either
change the form of the finished product or lead to interior holes. The metal may be stressed as
a result. The following list of shrinkage defects:

 Cracks from Open Shrinkage: Open shrinkage appears as a dip (also known as a caved
surface) or a cavity on the surface of a cast object. (also known as a pipe). These kinds of
flaws occur when metal contracts unevenly and pulls air into the mold in that region.
 Closed shrinkage defects: Holes within a casting are a common symptom of closed
shrinkage, which typically occurs where a portion of the liquid metal was hotter than the
remainder of the component. It can show up in either macro or micro shape. To the
unaided eye, micro shrinkage, also known as shrinkage porosity, appears as jagged scars
or lines. Only a lens will allow you to see the angular-looking holes. Warping: Warping,
which alters the casting's dimensions and form, can take place either during the metal's
solidification or after. In particular for big and flat casting sections, this stresses the
metal and results in curving.

Causes

 increased metal content in a particular area.

 pattern of casting complexity.
 The pressure on metal is inadequate.
  Poorly designed runners and gates.
 The metal is tainted.
 a smaller amount of metal during solidification

REMEDIES

 Add extra tolerance when designing the die.

 Use simple geometry in casting.
 Increased metal pressure.
 Modify the getting and runner style.
 Use simulation software to improve runner in order to have optimum filling of cavities.
 Remove the contamination, clean the metal surface.
 Provide core hole in middle and offset the ribs.

MOLD MATERIAL DEFECTS

Defects in the mold material are brought on by the mold material, but they can also be brought
on by issues with the mold construction. With seven primary kinds, this is the largest category
of casting flaws.

Cuts and washes occur when the flowing liquid metal erodes away a portion of the mold and
the sand is not sufficiently heat-resistant to stop it. Cuts and washes appear as low bulges along
the surface of the completed product, tilted toward the end where the molten metal flowed in
with greater force.

 Swells: On the completed piece, swells appear as a swollen area. These flaws occur
when the mold is too pliable, causing the sand to be forced outward by the weight of
the molten metal.
 Drops: Drops appear as erratic bumps on molds' tops. They occur when a mold is porous
and sand accidentally gets into the molten metal. Drops also muddy up the metal's
surface.
 Runout: This is when there is not enough metal to create the intended casting because the
mold has leaked.

CAUSES

As mentioned, the causes can differ depending on the defect created. The majority of flaws,
however, are either the result of using too-soft molds that require additional ramming or
pouring metal into them while they are still too hot.

REMEDIES

The best way to avoid all of these issues is to make sure the metal being poured isn't too hot
and that the molds receive enough ramming to hold the molten metal. If that doesn't work,
there are other approaches to resolving these problems, which vary from defect to defect.
Gate systems for cuts and washes may require redesign, or the sand may require more binders.
Reduce the amount of water in the sand in the mold to prevent swells.

POURING METAL DEFECTS

These flaws develop when pouring temperatures are too low, in contrast to many of the other
flaws. Three groups can be made out of them:

 Cold shot is made up of balls or drops that are loosely connected to the casting and are
the result of molten metal splatters that occurred during the pouring process. The
splatters become embedded or attached because they cool more quickly because they
are smaller than the remainder of the casting.
 Cold shuts happen when metal enters a mold from two or more places but is too cold to
combine into a single piece. At that point, it forms a crack with rounded sides running
through the center, which weakens the casting.

Causes

Poor gating system

Low melting temperature
Lack of fluidity
Remedies

Improved gating system.

Proper pouring temperature.

METALLURGIC DEFECTS

When a casting's metal has issues, there are metallurgical flaws that become visible. There are
three different kinds, including:

 Slag inclusion: When metal is not thoroughly cleansed of slag before being poured, slag
inclusion occurs. It simply means that there will be impurities or foreign material
embedded in the final casting. The appearance of the molds will be spongy or
honeycomb-like if the inclusion is dirt.
 Hot Tears: Also referred to as hot fissures, hot tears appear when cooling metal
contracts. When the metal is in this condition and still brittle, residual tension or a bad
mold design can cause the metal to pull apart, leading to branching, irregular cracks.
These can occasionally be challenging to see with the unaided vision.

CAUSES

i) The presence of slag in the molten metal

ii) Improper mold design.

Remedies

(i) Remove slag particles form the molten metal before pouring it into the mold cavity.
(ii) Proper mold design can easily eliminate these types of casting defects.
(iii) Elimination of residual stress from the material of the casting.

CASTING SHAPE DEFECTS

Casting flaws manifest as mismatches or flash depending on their form. Since they typically
require adjusting current molds, shape defects are among the simplest to correct.
  Mismatches, also known as shifts, occur when various casting components are not
properly aligned when they are supposed to be. Similar to core shift, misaligned cores
also experience vertical movement.
 Flash: Flash, which is also known as casting fins or burrs, appears as additional material
that is adhered to the casting, typically as a thin sheet that forms where sections of a
mold meet. One of the most typical casting imperfections is flash.

CAUSES

 improper top and lower part alignment during the mold-making process.
 flask misalignment (a flask is a sort of tool used to hold a mold in metal casting. It could
be rectangular, square, or any other form that is practical.)

REMEDIES

 Proper alignment of the pattern or die part, molding boxes.

 Correct mountings of pattern on pattern plates.
 Check the alignment of flask.