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Sand Casting Over View and

Defect Analysis
Rizky Haura N.S (6007201033)
Risca Awalia P (6007201004)

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 Definition Of Sand Casting
Sand casting is the most versatile among the
manufacturing methods and gives the Engineers the
freedom to design complex parts from an unlimited
number of metals and alloysIt is a metal casting
manufacturing process where the molten metal is poured
into the expendable sand mould cavity either by gravity or
by force, where it solidifies to form the cavity shape. A 3D
object formed by this process is also called casting. Most
common sand castings include Engine blocks, cylinder
heads etc. (
https://engineeringproductdesign.com/knowledge-base/sa
nd-casting/
)

In general sand casting is the process of metal

casting by using sand as a mold material.
Figure 1. Sand Casting
Source : www. Custompartnet.com
 Sand Casting Prosess

Source : http://www.dhf-china.com/news/the-process-flow-of-sand-casting.html
 Factors Causing Defects
1. Casting design and patterns

2. Sand, mold and core design.

3. The composition of the metal charge.

4. The process of smelting and pouring

5. Inlet and adder system.

International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
IJERTV4IS110511 www.ijert.org
Vol. 4 Issue 11, November-2015

Figure 2. Molten pouring on Sand Casting molds

Source : http.teknikmesinmanufaktur.blogspot.com
 Sand Casting
Defects

 Defects are defined as conditions in a casting

that must be corrected or removed, or the
casting must be rejected.
Classification According To The Source Of
Defects

Metallurgical defects : Porosity, Defects due to heat: Hot tears,

sinks, inclusion, dross, soldering. cold shut, thermal fatigue.

Mechanically induced defects:

Surface marks, bending, International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181

undercuts IJERTV4IS110511 www.ijert.org

Vol. 4 Issue 11, November-2015
Case Study
 The theme of the problem raised in our group's case study is the Defect
Analysis for Sand Casting process (Case Study in foundry of Kombolcha
Textile Share Company) written by Wossenu Ali (2010) of Wollo University,
Kombolcha Institute of Technology, Mechanical Engineering Department,
Kombolcha, Ethiopia
 Defect Analysis For Sand Casting Process (Case Study In Foundry
Of Kombolcha Textile Share Company)

This research aimed to identify the cause of casting defect and to suggest possible remedies in order
to produce conforming casting product in the foundry of Kombolcha textile share company, Ethiopia.
During casting defect analysis, the common casting defects blowholes, pinholes and shrinkage were
identified. The major and minor process variables which were responsible for each casting defects
were indicated using fishbone diagram.

For analysis of possible causes, Experiments were conducted for moulding sand to determine clay
content and grain fineness number (GFN). For defective part, composition analysis using spectrometer
was also done. Analysis showed that high clay content (52.7%) of moulding sand, wrong gating system
design, incorrect pattern design and unknown pouring temperature were responsible for the defects.

Experiment was conducted for remedial actions using reclaimed sand with grain
fineness number 40.19 and clay content of 1.5%, for correct gating system and
pattern design for casting of brake casing of weaving machine
Detection Of The Defect
 Detection Of The Defect
Almost all product of casting in this foundry are defective products. From the evidence, only
a few are acceptable casting product with certain tolerance, the majorities are rejected
product. As shown in figure 2.

Figure 3. a, b, c and d are examples of casting defects commonly occurred in the foundry
Source : Wossenu Ali, Jan 2020, Volume: 07 Issue: 01
 Identify the Symptoms and
Defining Defects

Table 1. Symptoms commonly absorbed and related defect types

Analysis Hi!
 The Following Were Experimental Tests

Clay content test Grain fineness Chemical composition analysis for

number test sample defective casted metal
 Clay content test

According to the Ot Jain (2007:4) mentions that In percentage, 52.7% of molding

sand is clay and 47.3% of molding sand is silica grain. Based on clay content test,
clay content of 52.7% is extremely contradictory to the recommended percentage of
clay for different types of moulding sands which uses for mould making process.
Based on their classification, maximum clay content is not more than 2% for high
silica sand and up to 10% for natural moulding sand
 Grain fineness number test

According to PL Jain (2007:4) mentions that Grain fineness number (GFN) 16.74 determined
by experiment is very small number, it indicates this sand is very coarse which has very small
fineness number less than the average fineness number which varies for cast iron from 45-65
and light alloys(e.g.Aluminium) 70-100.
 Chemical composition analysis for sample
defective casted metal

Table 2. Composition of cast iron sample

Source : Laboratory of Akake basic metals industry, Ethiopia.

All major causes and
sub-causes indicated
on the fish-bone
diagram were
experimentally tested
and practically
absorbed. Causes
which were
responsible for those
defects were
identified and
possible remedies
were suggested as
shown in the table
below.
 Casting experiment for
remedial actions
Hello!
In the sand casting experiments conducted by the
author using one of the common products, the weaving
machine brake casing, in the casting Kombolcha Textile
Share Company. The following corrective actions are
performed for this selected product.

Figure 4. Isometric view of brake casing

Source : Wossenu Ali, Jan 2020, Volume: 07 Issue: 01
 1. Change of moulding sand

Based on previous researchers the maximum clay

content is not more than 2% for high silica sand
and up to 10% for natural mold sand. The value of
Grain fineness number varies for cast iron from 45-
65 and light alloys(e.g.Aluminium) 70-100.
therefore the researchers changed the composition
of
Grain fineness number = 40.19
Clay content = 1.5%
Figure 5. Reclaimed moulding sand brought from foundry of Federal small and
micro enterprise development agency, Ethiopia
Source : Wossenu Ali, Jan 2020, Volume: 07 Issue: 01
 2. Pattern design
The pattern was designed and manufactured for
selected product by following the correct pattern design
procedure. It results the split pattern as shown below.

Type: split pattern

Material of pattern: Aluminum
Allowance: Contraction allowance of 10.5mm/M and
Machining allowance of 3mm were given for cast iron

Figure 6. Isometric view of split pattern

Source : Wossenu Ali, Jan 2020, Volume: 07 Issue: 01
 3. Design of gating system
Here design analysis for determination of pouring cup,
sprue size, choke area, runner size, pouring time
required, average filling time of the casting and effective
metal head of the casting was done. The following figure
is resulted dimensions of sprue, sprue well, and two gates
for gating ratio
4:1.

Figure 7. Dimension of Sprue, Sprue well and two gates in mm for gating ratio 4:1
Source : Wossenu Ali, Jan 2020, Volume: 07 Issue: 01
Procedures for Experiment

Figure 8. Procedures for Experiment

Source : Wossenu Ali, Jan 2020, Volume: 07 Issue: 01
Results and discussion
 Results and
discussion

Three experiments were conducted. Testing of moulding sand, clay content test (52.7%) and grain
fineness number (GFN) (16.74) indicated that the sand in this foundry is not moulding sand. It cannot use
for mould making process. Because the clay contained in the printed sand is very high beyond the
permissible limit, and makes the fluidity in molten pouring is not maximal so that there are defects in the
casting process, especially shrinkage cavity defects. For grain fineness number is also too rough so it
raises one of the defects Sand burn on.
Incorrect pattern design, wrong gating system design and uncontrolled melting process were
absorbed which were the causes for defects. In order to minimize those problems, correct working
procedure must be followed. For remedial actions, experimental test was done using other moulding
sand, correct pattern design and gating system design for brake casing of weaving machine. But the
problem absorbed during the experiment were difficulty in mould making and rough casting surface due
to coarseness of this reclaimed sand and sand burn on also absorbed.
Conclusions Hi!
 Conclusions

1. From defect analysis, the defects in this foundry were gas porosity
(blowholes and pinholes) and shrinkage porosity.
2. The main reason for these defects was high clay content (52.7%) of
the previous sand, unknown melting temperature, incorrect gating
system and pattern design.
3. Experiment for remedial action resulted with conforming casting
product for designed pressurized gating system (gating ratio 4:1).
This is because the flow is streamlined and defect due to turbulence
is avoided, the sand used for mould making has high permeability
therefore no air or gas entrapment which causes blowholes or
pinholes.
4. The pattern and gating system design were controlled to avoid
blowholes, pinholes and shrinkage.
5. For production of quality casting parts, this foundry must provide
other moulding sand and control of other process parameters during
pattern making, gating system design and pouring practice is
important.
Thanks
Do you have any
questions?

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