INSTITUTE OF SPACE AND TECHNOLOGY

SUBMITTED TO:
SIR ZEESHAN

SUBMITTED BY:
CHOUDHARY HASSAN RAWAIZ

ROLL NO.
210301041

SECTION:
MAT-14(B)
REPORT ON CASTING DEFECTS, CAUSES, AND
REMEDIES
Casting defects can significantly impact the quality and integrity of cast
products. Here are some common types:
1. Gas Porosity: Characterized by the presence of gas pockets within the
casting material, resulting in voids or holes.

2. Shrinkage Porosity: Occurs due to inadequate feeding of molten metal

during solidification, leading to cavities or voids in the casting.

3. Cold Shut: This defect arises when two streams of molten metal do not
fuse completely during mold filling, resulting in an incomplete casting
surface.
4. Hot Tear: Manifests as cracks in the casting caused by thermal stresses
during solidification due to inadequate material ductility.

5. Misrun: When the molten metal fails to completely fill the mold cavity
or solidifies before filling it entirely, leaving behind incomplete castings.

6. Inclusions: Foreign materials such as oxides, sand, or slag become

trapped in the casting, weakening its structure.

7. Blowholes: Similar to gas porosity, but blowholes typically appear as

spherical voids on the casting surface.
 8. Metal Penetration: Excessive intrusion of molten metal into the mold
material, resulting in irregular casting surfaces.

9. Scab: Thin layers of sand adhering to the casting surface due to mold or
metal erosion during pouring.

10.Runout: Excess molten metal flows out of the mold cavity, causing
irregularities or excess material on the casting surface.

2. CAUSES OF CASTING DEFECTS

Various factors contribute to casting defects, including:
1. Mold Material and Preparation:
Inadequate mold strength, improper gating
design, or incorrect mold temperature.
2. Casting Material Properties:
 Inappropriate composition, impurities, or incorrect
metal temperature.
3. Pouring and Solidification:
Improper pouring rate, inadequate control of
pouring temperature, or non-uniform cooling.
4. Mold Fill and Solidification:
Inadequate venting, improper gating, insufficient
mold rigidity, or metal penetration into mold materials.
5. Post-Casting Processes:
Inadequate cooling, improper handling, insufficient
cleaning, or incorrect heat treatment.
6. Environmental Factors:
Variation in temperature or humidity,
contamination of mold materials, or atmospheric gases reacting with
molten metal.
3. REMEDIES OF CASTING DEFECTS
Addressing casting defects requires a combination of preventive measures and
corrective actions:
1. Gas Porosity:
Enhance mold permeability, use degassing agents, and control
pouring techniques.
2. Shrinkage Porosity:
Optimize riser design and modify alloy composition to
control solidification.
3. Cold Shut:
Improve gating and pouring system design, and adjust pouring
temperature.
4. Hot Tear:
Modify alloy composition and implement proper cooling
practices.
5. Misrun:
 Ensure proper mold preheating, optimize pouring techniques, and
adjust pouring temperature.
6. Inclusions:
Implement proper metal handling and melting practices, use
high-quality refractory materials, and employ filtration systems.
7. Blowholes:
Improve mold venting, use degassing agents, and modify
pouring techniques.
8. Metal Penetration:
Optimize mold coating, control pouring parameters, and
improve gating design.
9. Scab:
Enhance mold coating, optimize pouring techniques, and implement
proper mold maintenance.
10.Runout:
Adjust pouring parameters, optimize gating design, and ensure
proper mold support.
Regular inspection, process optimization, and continuous improvement efforts
are crucial for effectively identifying and addressing casting defects in the
production process.