Casting Defects
1) Porosity
2) Shrinkage
3) Cuts and Washes
4) Swells
5) Rat Tails
6) Misruns
7) Cold shuts
8) Hot Tears
9) Mismatch
Porosity
Porosity takes place on casted metal when gasses (like nitrogen,
oxygen or hydrogen) trap during casting. The casting defect
appears on metals as small holes, rounded, or circular cavities.
Gas porosity casting defects are classified into two part-:
(i) Pinholes
(ii) Blowhole
Shrinkage
This type of casting defects occurs during the solidification of the
casting. This casting defect might also be paired with cracks.
Shrinkage with large cavities can cause the casting to eventually
break under stress. This defect should always be expected during
solidification.
Cuts and Washes
Cuts and washes can be caused by molten metal flowing at a high
velocity, causing too much metal to flow through the gate. A cut
appears as a low projection along the surface of the drag face,
decreasing in height as it extends from one side of the casting to
the other.
Rat Tails
This casting defect occur in the casting as an irregular
line or cracks. The rat tail appear on casting when
hotness of the metal causes the sand to expand which
may be caused by poor expansion properties of the
sand, hot pouring temperature of metal, and poor
design.
Swells
Swells typically take on the shape of a slight, smooth bulge on
the vertical face of castings. Swells are an enlargement of the
casting. Swell is usually caused by improper or soft ramming of
the mold or a low strength mold. Swells can be neglected by
using a strong, properly rammed mold.
Misruns
The liquid metal does not completely fill the mold cavity. The
misrun is the unfilled portion or space in the mold. Misruns occur
due to lack of fluidity, Faulty design, Faulty gating.
Cold shut
It appear on the surface of the casting. The defect leads to full
rejection of casting because it creates a weak spot. It is caused
when molten metal enters the mold from two gates, the steams
will meet at a junction. Low temperatures can prevent fusion at
the junction, causing the steams to solidify before fusion, creating
a cold shut.
Mismatch
Mold shift is due to misalignment of upper (cope) and
lower (drag) part of the mold. Mold shift is usually
reflected as a horizontal displacement.
Hot Tears
in this casting defects narrow cracks will take place in the pattern.
These cracks are seen after the casting cools, when it’s about to
solidify. Hot tear occurs if the casted metal does not have
sufficient strength to resist tensile forces during solidification and
it is mostly caused by poor mold design.
Cores
To obtain the desired cavities and recesses, which otherwise
could not be obtained by normal moulding operation.
• Full-scale model of interior surfaces of part
• It is inserted into the mold cavity prior to pouring
• The molten metal flows and solidifies between mold cavity and
core to form the casting's external and internal surfaces
Conti..
May require supports to hold it in position in the mold cavity
during pouring, called chaplets.
Core held in place in the mold cavity by chaplets with internal
cavity.
core print
The part of a foundry pattern which makes an opening in a mold
to receive a core and to support it while the metal is being
poured.
chaplet