19MEE202-MANUFACTURING

PROCESS -1
Lecture -9, Topic: Fettling, cleaning and inspection of cast
products and introduction to defects and remedies.
Class: 3rd Sem B.Tech-Mech A,B &C

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 Steps in Sand Casting

Fig: Outline of production steps in a typical sand-casting operation.

 Fettling

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 Fettling process conti…

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 Fettling process conti…
With cutting saw • These saws may be hand saw and power saw are used for
cutting the ferrous and non ferrous castings.
Mostly the hand saws are used for small and medium but when power and used for
large work.
With flame cutting , This type of method is specially used for ferrous materials of
large sized castings where the risers and gates are very heavy.

With abrasive cut of machine, These machines can work with all metals, hard
materials are difficult to grind

https://youtu.be/acrpjwrHT-o

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 Fettling process conti…
Removal of fins, rough spots and unwanted projections
The fins and other small projections may easily be chipped off with the help of
either hand tools or pneumatic tools.
But for smoothing the rough cut gate edges either the pedestal or swing frame
grinder is used depends upon the size of castings.

Cleaning Process
Sand blasting/ shot blasting /air blasting/ tumbling with hydro blast

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 SAND BLASTING /SHOT BLASTING
 Sandblasting refers to the process of propelling that
abrasive media with compressed air.
 This cleaning and preparation procedure takes
compressed air as a power source and directs a high-
pressure stream of abrasive media toward the given
surface.

 The term “Shot blasting” refers to the process of

propelling abrasive media material with centrifugal
or mechanical force.

 This abrasive treatment method uses a device similar

to a spinning wheel to centrifugally accelerate shot-
like material and blast it against a surface.

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 Classification of Casting Defects
1. DEFECTS DUE TO EVOLUTION OF GASES

(Blowholes, Pin hole, porosity, Dispersed shrinkage, Blister etc.,)

2. DEFECTS DUE TO POURING OF THE MELT

(Misrun, Cold shut, Inclusion, rat tail etc.,)

3. DEFECTS DUE TO METALLURGICAL FACTORS

(Hot tears)

4. DEFECTS CAUSED BY MOLDING MATERIAL

( Scab, Metal penetration, Flash, Run-out, Lug etc.,)

5. DEFECTS CAUSED DUE TO OTHER FACTORS

( Mismatch, Hot cracking, etc.,)

6. DEFECTS DUE TO SHRINKAGE

(Shrinkage cavity)
 Defects due to evolution of gases

1. Blow holes

2. Pin hole porosity

3. Dispersed shrinkage

4. Blister
 Blow holes

Causes
1. Excessive moisture in the mould
2. Slag in the metal reacts with carbon

in the metal and liberates CO.

3. Iron oxide on the mould wall reacts
With carbon in the metal and liberates CO.
 Blow holes

Remedial Measures
1. Provide vent holes
2. Avoid excessive compaction of
Mould
3. Avoid excessive moisture in the
Molding Sand
4. Extra care to be taken to segregate slag from liquid metal
5. Avoid using rusted chills and chaplets
 Pin hole porosity
• Large number of uniformly
dispersed tiny holes

Causes
Hydrogen is absorbed by the
molten metal inside the furnace
and also inside the cavity
As the melt gets solidified, it
loses the temperature and
liberates dissolved hydrogen
 Pin hole porosity

Remedial Measures
1. Vacuum melting
2. Vacuum degassing
3. Avoid very high pouring temperatures
 Dispersed shrinkage
• Small shrinkage cavities dispersed throughout the casting
Causes
1. Excessive moisture
2. Very high pouring temperature

Remedial measures
Appropriate moisture and pouring
temperature to be taken.
 Blister
• Bubble like bumps
Causes
1. Gases trapped in the cavity cause
depressions on the mould surface.
2. Insufficient strength of mould cavity
At some locations.

Remedial Measures
2. Ensure sufficient and uniform
Compaction of the mould.
 Defects due to pouring of the melt

1. Misrun
2. Cold shut
3. Slag or dross Inclusion
 Misrun
• The liquid metal does not completely fill the mold cavity. The
misrun is the unfilled portion or space in the mold.
 Mis-run

Causes
1. Insufficient fluidity
2. Low pouring temperature
3. Too small ingates
4. Low pouring speed

Remedial Measures
5. Increase pouring temperature
6. Increase pouring speed
7. Make ingates larger
 Cold shut

• The molten metal streams from different ingates are not fused
together properly, causing a discontinuity or weak spot.
Causes
1. Longer distance between the ingates
2. Large surface area to volume ratio

Remedial Measures
1. Use more number of ingates
2. Increase the pouring
temperature
 Inclusions
• Undesirable foreign materials present in the metal (oxides,
slag, dirt etc.,)
Causes
1. Impurities present in the molten metal
2. Sand cracked and broken from gating system and mould
cavity
 Inclusions

Remedial Measures
1. Skimming of molten metal before pouring
2. Choosing a molding sand with adequate hot strength
3. Using ceramic foam filters
 Defects caused by molding material

1. Flash
2. Run-out
3. Scab
4. Metal penetration
 Flash
• Molten metal flows into the gap between cope and drag
Causes
1. Sand is not properly compacted along
The parting line
2. Small gap exists between cope and drag
 Flash

Remedial Measures
Molding sand should be leveled properly
along the parting line
 Run-out
• It is different form flash
• Hydrostatic pressure of the liquid metal lifts the cope
• Metal flows along the parting line
Causes
1. The cope rises up during pouring of the metal, due to
hydrostatic pressure of the poured metal
2. Insufficient weight of the cope
Run out is when liquid metal leaks
out of the mold, leading to an
incomplete or missing casting.
 Run-out

Prevention of run out and incomplete castings

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.
 Scab
• Liquid metal flows beneath the mould surface and mixes with
molding sand
Causes
1. Low moisture content in the molding
Sand (below 3%)
2. Insufficient clay in the molding sand. low binding strength of
moulding material or sand
 Metal penetration
• Metal goes inside the mould. This defect occurs when fluidity
of molten metal is high.
Causes
1. Larger sand grains
2. Insufficient compaction of sand
 Metal penetration

Remedial Measures
1. Use fine sand grains
2. Reduce casting temperature
3. Apply sufficient compaction of mould
 Defects due to metallurgical factors

Hot tear
Hot tearing is the macroscopic separation due to differential
contraction of the casting during solidification.

Causes for Hot tears

The casting could not undergo shrinkage freely during
solidification, due to casting design or presence of cores
 Other factors Influencing Hot Tears

1. Chemical composition – High sulphur content promotes hot

tearing.
2. Long freezing range

Remedial Measures
3. Use exothermic pads
4. Control the composition-minimize sulphur content in the
liquid metal
5. Use grain refiners (Al-8B, Al-3B etc.,)
 Defects caused due to other factors

1. Mismatch
2. Hot cracking
 Mismatch
• Mismatching of top and bottom parts of the casting
Causes
Misalignment of molding boxes
Remedial Measures
1. Ensure proper alignment of
molding boxes
2. Replace worn-out dovetail pins
by new ones
 Hot cracking
It is different from Hot tearing

Causes
- Due to un even cooling in the mould
- During knocking out

- During heat treatment cycle

- During cooling after knock-out

Remedial Measures

1. Use chills

2. Use fillets
3. Avoid rough handling
 Defects due to shrinkage

Causes
1. Insufficient size of the riser
2. Improper positioning of the riser

3. Premature freezing of liquid metal in the riser

4. Abrupt changes in the casting design

Remedial Measures
5. Design the riser sufficiently large
6. Ensure Directional Solidification
 Shrinkage cavity

Starting level of molten metal Reduction in level caused by

immediately after pouring liquid contraction during cooling
 Shrinkage cavity

Reduction in height and formation Further reduction in height

of shrinkage cavity caused by and diameter due to thermal
solidification shrinkage contraction during cooling of
the metal
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Shot blasting machine
https://www.youtube.com/watch?v=W11Q2H_cT6o

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