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CASTING DEFECTS
There are numerous opportunities for things to go wrong in a casting
operation, resulting in quality defects in the cast product. Some defects
are common to any and all casting processes.
1. Misruns, which are castings that solidify before
completely filling the mold cavity. Typical causes
include (1) the fluidity of the molten metal is
insufficient, (2) pouring temperature is too low, (3)
pouring is done too slowly, and/or (4) cross-section
of the mold cavity is too thin.
2. Cold Shuts, which occur when two portions of
the metal flow together but there is a lack of
fusion between them due to premature freezing.
Its causes are similar to those of a misrun.
3. Cold shots, which result from splattering during
pouring, causing the formation of solid globules
of metal that become entrapped in the casting.
Pouring procedures and gating system designs
that avoid splattering can prevent this defect.
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4. Shrinkage cavity is a depression in the surface
or an internal void in the casting, caused by
solidification shrinkage that restricts the
amount of molten metal available in the last
region to freeze. It often occurs near the top of
the casting, in which case it is referred to as a
‘‘pipe.’’ The problem can often be solved by
proper riser design.
5. Microporosity consists of a network of small voids distributed
throughout the casting caused by localized solidification shrinkage of
the final molten metal in the dendritic structure. The defect is usually
associated with alloys, because of the protracted manner in which
freezing occurs in these metals.
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6. Hot tearing, also called hot cracking, occurs
when the casting is restrained from contraction
by an unyielding mold during the final stages
of solidification or early stages of cooling after
solidification. The defect is manifested as a
separation of the metal (hence, the terms
tearing and cracking) at a point of high tensile
stress caused by the metal’s inability to shrink
naturally.
• In sand casting and other expendable mold processes, it is prevented
by compounding the mold to be collapsible.
• In permanent mold processes, hot tearing is reduced by removing the
part from the mold immediately after solidification.
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Some defects are related to the use of sand molds, and therefore they
occur only in sand castings. To a lesser degree, other expendable-mold
processes are also susceptible to these problems. Defects found primarily
in sand castings are:
1. Sand blow is a defect consisting of a balloon-shaped
gas cavity caused by release of mold gases during
pouring. It occurs at the casting surface near the top of
the casting. Low permeability, poor venting, and high
moisture content of the sand mold are the usual
causes.
2. Pinholes, also caused by release of gases
during pouring, consist of many small gas
cavities formed at or slightly below the surface
of the casting.
3. Sand wash, which is an irregularity in the
surface of the casting that results from erosion
of the sand mold during pouring, and the
contour of the erosion is formed in the surface
of the final cast part.
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4. Scabs are rough areas on the surface of the casting due to
encrustations of sand and metal. It is caused by portions
of the mold surface flaking off during solidification and
becoming imbedded in the casting surface.
5. Penetration refers to a surface defect that occurs when the
fluidity of the liquid metal is high, and it penetrates into
the sand mold or sand core. Upon freezing, the casting
surface consists of a mixture of sand grains and metal.
Harder packing of the sand mold helps to alleviate this
condition.
6. Mold shift refers to a defect caused by a
sidewise displacement of the mold cope
relative to the drag, the result of which is a
step in the cast product at the parting line.
7. Core shift is similar to mold shift, but it is
the core that is displaced, and the
displacement is usually vertical. Core shift
and mold shift are caused by buoyancy of
the molten metal.
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8. Mold crack occurs when mold strength is
insufficient, and a crack develops, into which
liquid metal can seep to form a ‘‘fin’’ on the final
casting.