Group Members:

Abdul Razzaq 15-IME-112

Tuba Zubair 15-IME-126

Hanzala Ahmad 15-IME-121

 Project Title:
Casting Defects and Their Remedies
in
Green Sand Casting
Project Supervisor:
Dr. Qasim Ali Ranjha
Co-Supervisor:
Engr. Muhammad Shahzad
What is Casting?

Casting is a manufacturing process in

which a liquid metal or alloy is usually
poured into a mold, which contains a
hollow cavity of the desired shape, and
then allowed to solidify. The solidified
part is also known as a casting, which is
ejected out of the mold to complete
the process.
Types of Casting Processes:
 Sand Casting.
 Permanent Mold Casting.
 Investment Casting.
 Lost Foam Casting.
 High Pressure Die Casting.
 Centrifugal Casting.
 Glass Casting.
Sand Casting:
 Sand Casting is a process in which a cast is
produced from a molten metal in a sand mold.
 Typically cast iron, but also steel, bronze, brass,
aluminum, magnesium, certain zinc and Nickle-
based alloys are used in a green-sand mold.
 Sand castings are produced in specialized
factories called foundries. Over 70% of all metal
castings are produced via a sand casting process.
 e.g. Centrifugal Pump and Motor body, Engine
Block, Gears, V-Block Clamp, Anvil etc.
General Sand Casting:
Types of Sands:
According to their use in foundry, molding sand is
classified into following different types:
 Green sand-Mixture of sand, clay, water, Binders
(Molasses or Linseed oil).
 Dry sand-Organic binders rather than clay.
 Loam sand-Mineral composition of sand-silt-clay.
 Facing sand-Silica sand and clay.
 Baking sand
 Parting sand
 System sand
 Core sand etc.
Green Sand:
 The expendable molds are made of wet sands
that are used to make the mold's shape.
 Green sand is not green in color, but "green"
in the sense that it is used in a wet state (akin
to green wood).
 Unlike the name suggests, "green sand" is not
a type of sand on its own, but rather it’s a
mixture.
Materials used for Green Sand Molds:

 75 to 85% Silica Sand (SiO2), Chromite

Sand (FeCr2O), Zircon Sand (ZrSiO4),
Olivine, Staurolite or Graphite.
 5 to 11% Bentonite Clay.
 2 to 4 % Water.
 3 to 5% Inert Sludge.
 0 to 1% Anthracite i.e. Hard coal.
Green Sand Casting:
 Green sand casting process is relatively
inexpensive and can also use to make very
large castings.
Casting Defects:
Any unwanted deviation from the desired
requirements in a cast product results in a defect.
Some defects in the cast products are tolerable while
others can be rectified by additional processes like
welding etc. The following are the major defects
which are likely to occur in sand castings:
 Gas defects
 Shrinkage cavities defects
 Moulding material defects
 Pouring metal defects
 Metallurgical defects
Gas Defects:
Causes:
Due to Lower gas passing tendency i.e. Lower Venting.
Lower permeability of the mould.
Improper design of the casting.
Remedies:
Adequate venting facility should be provided.
High permeability of sand should be used.
Proper alignment of pattern, die part or molding boxes.
Shrinkage Cavities Defects:
Causes:
 An improper riser and gating system.
 Poor design of casting involving abrupt changes in
thickness.
 High pouring Temperature.

Remedies:
 Carry out proper ramming.
 Maintain optimum pouring
temperature and time.
Moulding Material Defects:
Causes:
 Insufficient strength.
 Improper ramming.
 High pouring Temperature.

Remedies:
 Sufficient strength should be provided.
 The sand should be rammed properly and evenly.
 The Pouring temperature should be maintained to a
specified range i.e. Sand can withstand temperatures
as high as 1650-1820ᵒC
Moulding Material Defects:
Pouring Metal Defects:
Causes:
 Low temperature of molten metal.
 Slow and intermitted pouring.
 Improper alloy composition and gating system.
 Use of damaged pattern.
Remedies:
 Smooth pouring.
 Arrange proper clamping arrangement.
 Providing appropriate pouring temperature.
Metallurgical defects:
Causes:
 Improper casting Design.
 Very hard ramming.
 Too much shrinkage of molten metal.
 Incorrect pouring temperature.
 Improper gates and risers.
 Low flowability of molten metal.
Remedies:
 Use soft Ramming.
 Modification in pattern to take care of
residual stresses
Objective:
 To identify various Casting Defects in Green
Sand Casting Process and suggest possible
remedies to remove these defects.
Methodology:
The following steps will be involved:
 Problem Statement.
 Literature Survey.
 Visit of various foundries.
 Identification of different casting defects in
green sand castings.
 Suggestion of possible remedies.
 Observations and comments.
 Writing of report.
Proposed Outcomes:
 At the end of this study, we will be able to
improve the Green Sand Casting Process to get
good quality product.
 The result of this study may help the local
industry to improve the Green Sand Casting.
 The data obtained may be published .