CASTING DEFECTS

DEFECTS- Any uncontrolled parameter in molding process develop a product which deviates in
quality (properties,size,dimension,accuracy) w.r.t required part. The deviations are casting defects.
These defects can be eliminated/reduced by using proper molding practice or controlling the
parameters.
Blow holes- spherical/flattened/elongated
Major defects- cavities present inside casting or at the high
i) gas defects- blow holes, pin hole porosity, point on the surface causing open blow holes.
air inclusion Developed as gas does not flow thru. Caused
due to excessive moisture, inadequate porosity,
ii) Shrinkage defect
poor venting, improper cleaning of chaplets etc.
iii) Molding material defect- cuts and washes,
Pin hole porosity- this defect is caused in the
metal penetration, run out, swell, drop
form of fine pins by Hydrogen which evolve out
iv) Pouring metal defect- mis run, cold shut, when molten metal temp. reduces.
slag inclusion
Air inclusion- escaped air which was absorbed
v) Metallurgical defects- hot tears, hot spots in furnace or during flow in mold.
In the ladle (aka tank) degassing method, the ladle is placed into a vacuum chamber,
the chamber is sealed and a vacuum of 0.7 – 13.0 mbar (0.5 mm – 10.0 mm Hg) is
applied. An alternate design uses the ladle itself as the vacuum chamber. In this design,
the lid is designed with a vacuum tight seal between itself and the ladle. In order to
ensure that the necessary surface area of molten steel is exposed to the vacuum, the
steel is stirred so that new steel is constantly being brought to the surface. This is done
by blowing an inert gas such as argon up through the molten steel.
Cuts and washes- rough spots and excess
metal deposition caused by erosion of sand mold
due to flow of metal

Metal penetration- molten metal penetrate

inside gap of grains causing a rough surface.
Common cause- coarse grain, no wash/cleaning
of mold cavity, higher pouring temp. of metal
Run out- leaking of molten metal from mold.
Due to faulty mold design/faulty mold flask
design or alignment
Swell- metallostatic pressure compress mold
material to enlarge cavity. Reason- improper
ramming
Drop- dropping of loose sand from cope
surface to mold cavity. Improper ramming,
insufficient binder is the reason
Misrun- incomplete cavity filling.occurs due to
inadequate supply of molten metal, low pouring
temp, improper design of gate, low fluidity of molten
metal, too large (surface area/volume) ratio i.e low
thickness
Cold shut- while meeting two metal strem do not
fuse and make a weak spot.
Slag inclusions- slag is caused due to use of flux
during melting. Slag work as impurity and reduces
the quality of part. Therefore, it is trapped/removed
by different slag removal technique in mold design
or by using screen in pouring basin.
Hot tears- hot crack appear in irregular shape with
dark oxidized fracture surface.it happens when hot
metal is unable to resist cooling stress during
solidification. Occur due to- high temp of cast metal,
improper design of gate, abrupt change in section.
Hot spots- defect of specific material like GCI . it
become hard white cast iron due to chilling
FUSION- glassy appearance of cast and surface
become brittle as sand grain burns and fused with
molten metal. Due to higher pouring temp/ low
refractoriness