LIST OF DEFECTS IN CASTINGS

01. Shrinkage
02. Cold Shut
03. Mismatch
04. Blow holes
05. Pin Holes
06. Fin
07. Drop
08. Swell
09. Metal Penetration
10. Hot Tears
11. Porosity
12. Scabs
13. Hard Spots
14. Buckles\Rat Tails
15. Misrun
 SHRINKAGE
Shrinkage cavity is a void on the surface of
the casting caused mainly by uncontrolled and
improper solidification of the metal.

Causes:
-inadequate
inadequate and improper gating
-poor design of casting involving abrupt
changes in thickness
-too high pouring temperature
Remedies:
-pour at correct temperature
-modify gating, runner and riser system
 Cold Shut
It is the imperfect
mperfect fusion of molten metal in the
mould cavity.

Causes:
-low pouring temperature
-improper gating system
-insufficient molten metal in the ladle for one
pouring

Remedies:
- pour at correct temperature.
- provide correct gating system.
- pour sufficient molten metal in the ladle for one
pouring.
 Mismatch
It is a shift /misalignment between the two
casting sections.

Causes:
-Worn-out dowels in patterns made in halves.
-Improper alignment of mould boxes due to
worn out or bent clamping pins.
- Misalignment of moulding boxes
Remedies:
- Repair or replace the dowels and clamping
pins.
- Properly clamp the boxes.
 Blow Holes
The voids caused by release of mould gases
during pouring are known as blow holes.

Causes:
-excess moisture in sand
-hard ramming
-improper venting
-excess binder
Remedies:
-control moisture content
-ramming should be carried out properly.
-provide sufficient vent holes.
-control binder content.
 Pin Holes
Pin holes are tiny blow holes appearing just
below the casting surface.

Causes:
-sand with high moisture content.
-absorption of hydrogen/carbon monoxide gas
in the metal.
-alloy not being properly degassed.
-steel is poured from wet ladles.
-sand containing gas producing ingredients.
Remedies:
-reducing the moisture content of moulding
sand.
-increasing its permeability.
-employing good melting and fluxing practices.
-improving a rapid rate of solidification.
 Fin
Fins are excessive amounts of
metal created by solidification into the
parting line of the mold

Causes:
-inadequately
inadequately weighted sand as well as
incorrectly assembled mould
moulds and cores.
-over
over flexible bottom boards.
-loose
loose plates and improper clamping of flasks.
Remedies:
-correct assembly of the mouldand cores used
for casting.
 Drop
Drop is an irregularly-shaped projection on
the cope surface caused by dropping of sand.

Causes:
-low green strength of the moulding sand.
-low mould hardness.
-insufficient reinforcement of sand projections
in the cope.
Remedies:
-moulding sand should have sufficient green
strength.
-ramming should not be too soft.
 Swell
Swells are excessive amounts of
metal in the vicinity of gates or beneath
the sprue

Causes:
-insufficient
insufficient or soft ramming.
-low
low mould strength.
-mould
mould not being adequately supported.
Remedies:
-sand
sand should be rammed evenly and properly.
 Metal Penetration
Penetration occurs when the molten
metal flows between the sand particles in the
mould. These defects are due to inadequate
strength of the mold and high temperature of
the molten metal adds on it.

Causes:
-low strength of moulding sand.
-large size of moulding sand.
-high permeability of sand.
-soft ramming.
Remedies:
-use of fine grain with low permeability.
-appropriate ramming.
 Hot Tears
A hot tear is a fracture formed during
solidification because of hindered
contraction
contraction.
Causes:
-faulty casting design leading to excessive
stresses at certain portions in the casting.
-very hard ramming.
-too much shrinkage of molten metal.
-incorrect pouring temperature.
-improper gates and risers.
-low flowability of molten metal.
-high sulphur content in molten metal.
Remedies:
-ramming should not be too hard.
-modification in pattern to take care of residual
stresses.
 Porosity
Porosity is pockets of gas inside the
metal caused by micro
micro-shrinkage
shrinkage during
solidification.

Causes:
-dissolved
dissolved hydrogen and sulphur dioxide in
molten metal.
-excessive
excessive poring temperature.
-slow
slow rate of solidification.
-high
high moisture content of the mould.
Remedies:
-maintenance of proper melting temperature.
-casting should be made to solidify quickly by
using proper gating and risering.
-permeability of the mould should be increased.
-moisture content of mould should be kept low.
 Scabs
Scabs are surface slivers caused by
splashing and rapid solidification of the
metal when it is first poured and strikes
the mold wall

Causes:
-insufficient
insufficient strength of mould and core.
-uneven
uneven mould ramming.
-lack
lack of binding material in facing as well as
core sand.
-Faulty gating.
-intense local heating due to slow running of
molten metal over sand surface.
Remedies:
-appropriate ramming.
-improved gating system.
-addition of sufficient binders in facing and core
sands.
 Hard Spots
These spots are formed due to the local
chilling by moulding sand which leads to the
formation of white cast iron at those places,
rendering them hard.

Causes:
--faulty metal composition.
-faulty casting design resulting in relatively
more rapid cooling of certain spots.
Remedies:
-modification of casting design.
-modification of casting composition.
 Buckles/Rat Tails
Rat tail or a buckle is a long, shallow,
angular depression caused by expansion of the
sand.

Causes:
-excessive mould hardness.
-lack of combustible additives in the moulding
sand.
-continuous large surfaces on the casting.

Remedies:
-suitable addition of combustible additives to
moulding sand.
-reduction in mould hardness.
-modifications in casting design.
 Misrun
When the molten metal fails to fill the
entire mould cavity before the metal starts
solidifying , resulting in an incomplete casting,
the defect is known as misrun.

Causes:
-low temperature of molten metal
-improper gating system
-too thin casting sections
-slow and intermitted pouring
-improper alloy composition
-use of damaged pattern

Remedies:
_ Smooth pouring with the help of monorail.
_ Properly transport mould during pouring.
_ Arrange proper clamping arrangement.
-providing appropriate pouring temperature.