ANA Y I I

A IN DE ECTS

Prepared by

Analysis of Casting
Defects Committee

First Edition
1947

Publisbed by
AMERICAN FOUNDRYMEN'S ASSOCIATION

222 \'(T. ADAMS ST. CHICAGO 6, ILLINOIS

 , , fill f

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11111111111111111/1' .uu l l'lilllillill(' dl'l'('( t i vr: c:lslings, 'I()~I or lilt' Ill'll -,
11.1iII.I~ iI('('11plt'~I'IIII'd PI'('\ i(lIl~1 ill lile rOl'111of lalks. Fr In ih
Copyright, 1947 III ,111\ I('SPOIIM' III('M' I;ilks received, it. is ' it! nt that there is a
l'llllll~ 1I('('d 101' a hook Oil ca ling d ( ct .
BY THE ()I i .ill:lil iuu-udcd primarily [or gray iron founders and pre-
p.IIt'1i h III 'It primarily as ociated with the gray iron field, this
AMERICAN FOUNDRYME 's ASSOCIATION hllnk i.~ a luahle 10 all Ioundryrnen. Only four of the defects de-
Ii ilwd (mass hardn ,hard pots, inverse chill, kish) are peculiar
INCORPORATED III gl:l iron, while the others occur at some time in all foundries.
I:I~' hurc!n s and hard spots may also occur in other types of
222 West Adams Street, Chicago 6, Ill. ,iII() 's but nOLn ccssarily for the reasons shown in this book.
<::lsiing cl Iccts may be of three types: I-major defects which
uu.kc th asting a total loss; 2-defects which cost so much to re-
JIlliI' Iha tit is q ucstionable whether to salvage or scrap the casting;
:1 minor d lccts which allow economical salvage of the casting.
Although all defective castings cannot be classified as scrap, a
lid Live casting always represents a loss to the foundry producing
it. Ev n th ugh slightly defective castings can be salvaged, there
is an xpenditure of time and material which affects the profitable
opnaLion of a foundry.
All rights reserved, This book., or Thirty-one basic casting defects are listed and described. Each
parts thereof, rk-Icct j defined in terms which are simple yet sufficiently complete
IC) make the defect recognizable. Illustrations show typical defects
may not be reproduced
.uul supplement the definitions.
in any for",
Th list of defects is shorter than the original number published
without permissio» of
in lil't' ov mber 1941 issue of AMERICA FOUNORYMAN.Many of
the P1l blisbers Iill' dde rs originally listed were found to be basically the same .
. rites have been combined and are now listed as one defect. The
obj Lof the committee has been to find the basic defects and then
uut lin the fundamental causes. It is only by eliminating the
l'undamental cause or causes that a foundryman can successfully
('Ii 111 ina te the defect. '
Until 1939 progress in the study of defects was slow, although
Wilt good was accomplished by a committee known as the "Inter-
11:11ional Relations Committee to Study Foundry Defects, Causes
nnd Remedies." This small group tried to cover the entire casting
industry. In 1939, C. P. Fuerst of the Falk Corp. of Milwaukee,
rha irman of the committee, together with "V, A. Hambley, then
or Ilis-Chalrners Mfg. Co., Milwaukee, and R. E. Kennedy, then
SI'(T tary of the American Foundrymen's Association, planned a
PRINTED IN U.S.A. working committee for each branch of the industry.
 'I'll(' 1'1t' t'llI filii 11I11 r uuuu III't' IV I tlig Ildlt'd ill IHIO III lilt' 7" 1,1, ., 'If) .t, lit
nuuuul livc muu
I"
(OIlVC'IIIioll or Iht' ss()(i:JllOIl ill Chkago.
board 'ollSislillg or w. . l lumhlcy, to:..J.Cnnuody, F. L. l l iutz,

I I Illu trutl n viii

. . Kawin and A. . i hols J' aliz d th mmiu w uld need xi
IIlIw I ) U hi Book
help and offered to ponsor it. The men were P ially hell Iul
111111 f of Gray Iron Casting Defects xii
during the formative period, furnishing a place to meet and study,
acting as coordinators and performing some of the practical found- I ,w u Hol s, Porosity, Pin Holes and Blisters 1
ry tests. m and Plates 19
Much of the detailed study of casting defects was accomplished 24
r Cold Shots .
in the foundries of the Allis-Chalmers Mfg. Co. through the co-
Cavities and Depressions 25
operation of J. M. White, Vice President, H. E. Ladwig, Works
Manager of the Foundry Division, and J. T. Jarman, General I' I I rr and Cracks 34
Superintendent of the Research Dept. The photographs are the Mil H rdness ~. 39
work of Rexford Krueger, Chief Metallographer of Allis-Chalmers 42
I" II I pots: Hard Areas and Chilled Spots
Mfg. Co., and his staff.
Other outstanding contributors to this work are: G. W. Ansel- Willi d Castings 46
man, Goebig Mineral Supply Co., Chicago; T. E. Barlow, Eastern I' II Grain Structure 48
Clay Products, Inc., Jackson, Ohio; E. J. Carmody, C. C. Kawin M run and Cold Shuts 52
Co., Chicago; A. S. Klopf, The Western Foundry Co., Chicago; 55
It III I ns: Dirt, Slag and Other Material
W. B. McFerrin, Electro Metallurgical Co., Detroit; F. L. Over-
III und Washes 61
street, Illinois Clay Products Co., Chicago; Charles Zahn, Vilter
Mfg. Co., Milwaukee, and W. C. Wine, Sibley Machine and Foun- 1111 n Scabs 65
dry Corp., South Bend, Ind. I P In ion Scabs: Buckles, Rattails, Blacking Scabs and Pulldowns 70
I u h s, Push-ups and C1amp-offs 78
For.,..er Co.,...,..ittee Me.,..bers 81
III I
A. J. Busch, C. C. Kawin Co., Chicago.
,I k rs or Rats 84
R. K. Glass, Republic Steel Corp., Buffalo, .Y.
F. L. Hintz, first committee secretary, formerly of Illinois Clay I u h Surfaces 87
Products Co., Chicago. Mil Penetration 89
J. L. Love, formerly of Battelle Memorial Institute, Columbus, 94
III n
Ohio.
'v« II Fins, Strains and Sags
I
95
C. V. Nass, Pettibone-Milliken Corp., Chicago.
A. S. Nichols, Illinois Clay Products Co., Chicago. , II fl . 97
W. G. Reichert, consulting engineer, Newark, N.J. Raise
I' 100
F. L. 'Weaver, Great Lakes Foundry Sand Co., Detroit. 103
I urnoff or Ramaway
r : Wrong Cores, Improperly Set Cores and Omission of
Final Co.,...,..ittee
Cores 105
'!\T. A. Hambley, chairman, Falls Mfg. Co., Menomonee Falls,
Wis. Illn uts and Bleeders 107
A. S. Klopf, secretary, The Western Foundry Co., Chicago. III k n Castings . 112
G. W. Anselman, Goebig Mineral Supply Co., Chicago. lnv rse Chill . 113
T. E. Barlow, Eastern Clay Products, Inc., Jackson, Ohio. 116
E. J. Carmody, C .C. Kawin Co., Chicago.
I' ur d Short.
W. B. McFerrin, Electro Metallurgical Co., Detroit. Ih 117
F: L. Overstreet, Illinois Clay Products Co., Chicago. I f ctive Test Specimen . 118
Charles Zahn, Vilter Mfg. Co., Milwaukee. hI X. 119
 111111 I II'
',It I Ilk III II , till I • ').9

" r (I Iln J o
Figure Page 111101 , cl VI w 'f hrlnk 31

1. Blows Caused by Combination of Four Factors 4 lilt I" tI App rcnc of hrlnkog D f ct 31
"1\llnk au d by Improp r Metal Composition or Inadequate Riser 32
2. Pin Holes Caused by Excessive Moisture 5
hrlnk R ultlng from Unbalance between Composition and Section Size 33
3. Blow Caused by Wet Sand and Hard Ramming 6
, tlng Cracked by Strongly Reinforced Core 37
4. Blow Incorrectly Called a Pulldown • 7
III. rock d Casting Caused by lack of Core Collapsibility 37
5. Pin Holes Due to Excessive Permeability and Moisture 7
1';. hill d Casting Cracked when Composition was Incorrect • 38
6. Blow Caused by Foreign Matter in Molding Sand. 8 10. hili Test Blocks which Illustrate Effect of Blast Variation 40
I 7. Blow Due to Hard Ram-up Core 9 ·11. ffect of Accidental Use of Stainless Steel Scrap in Cupola Charge 41
I .I~. Hard Spots Due to Improper Use of Core Wash 43
I' 8.

9.
Enlarged View of Blow in Manifold

Blow in Diesel Engine Head Due to Excessive Gas

9

10 t '\. Chilled Edges Caused by Wrong Metal Composition 44

~~. Effect of low Carbon Equivalent on Small Section. " 45
10. Diesel Engine Head Blow Magnified Three Times 10
I 11. Blow Showing Entrapped Core Sand 11
~ I. Hard Spot Caused by Undissolved Addition of Ferrochromium 45
1\ Warpage Due to Poor Design 47
12. Blow Due to Excessive Core Gas 12
I 13. Blow which Appears to be a Shrink 12
1\1'.
~
Open Grain Caused by High Carbon Equivalent Iron.
Casting Illustrating Three Defects
50
51
I 14. Casting Sectioned to Show Core Blow 13 49. Misrun Due to Cold Metal 54
15. Blow Due to Condensation of Moisture from Hot Sand on Cold Core 14 O.
I Misrun Caused by Int~rrupted Pouring 54

16. Blow Resulting from Insufficient Permeability 14 1. Slag Inclusions Resulting from Poor Gates 57
2. Inclusions Caused by Boiling Iron 57
17. Blister Caused by Hard Ramming and Wet Sand 15
3. Inclusions Caused by low Strength Sand 58
18. Blister as It Appears after Cleaning 15
'4. Drag View of Casting Containing Inclusions 58
19. Blows Caused by Cold Metal 16
5. Crush at Core Print Caused Inclusions 59
20. Gas Holes Caused by Damp ladle 16
"6. Inclusions Resulting from Careless Molding 59
21. Pin Holes Caused by Non-ferrous Contaminants 17 7. Copper Inclusion Due to Improper ladle Addition 60
22. Blow Holes Resultingfrom Foreign Metal in the Charge 17 8. Cuts or Washes Caused by low Strength Sand 63
23. Chaplet Blow Compared with Sound Casting 18 59. Inclusions Resulting from Cuts and Washes. 64
60. Erosion Scab Due to Hard Ramming or High Moisture. 66
24. Plate Caused by Excessive Ramming 21
61. Erosion Scab Caused by Gating System 67
25. Enlarged View of Plate. 22
62. Erosion Scab which Produced Sand Inclusions 68
26. Plate Caused by Wet Sand and Hard Ramming 23
63. Erosion Scab Accompanied by Gas Holes and Inclusions 69
27. Cross-sectional View of Plate and Casting. 23
64. Expansion Scab Due to low Clay in Sand • 72
28. Shrink or Porosity Caused by lack of Feed Metal during Solidification. 26 65. Casting with Expansion Scab, after Cleaning 73
29. Shrink Resulting from lack of Feed Metal 27 66. Buckle and Veins of Metal under Expansion Scab 73
30. Shrink Due to Ineffective Riser 28 67. Rattail Caused by low Clay in Sand 74
 tI \/I I I

60. Id hvt uu I I y Uv kl whl h R Iv d tl II fhl kn 7 """ ", J, ','/.

69. Rattail in op of T t Co ting 76 1\111111111111 1111'1111011'l.lIldlllt'PIOhl('IIIOI'(OI'It'(lillg'IIi'C"IIIS('S
ell (.1 IiliH dl·II'( I 011SOliII' Iillll' :lIld 100011('11 itaV(' hl.uucd d if'c I.'
70. Expansian Scab Cvred by increasing Clay in Sand 77 elll (IIII'II'.MII('S, Thl' Ildid Illal clt'/'('('IS arc C<llIS'(\ primarily by
71. Two Views of a Blacking Scab • 77 e,III'II'SSIII'SSis f:cls(' ill IIt(' l1lajoril.Y f as. onscqu nrly, the
72. Push-up in Drag Side of Casting 80 (:IIIIIIIIiIl('t' Oil lIalysis f 'asLing D f LS r commends that
73. Crush in Camshaft Gear Blank • 80 luuu dr nu-u cf imin.u . d f uv a ting by locating and eliminat-
iIll-(lil(' basi .. <1 us S. 1his will give the only effective permanent
74. Drop Caused by Rough Handling 82
I t lI'l'.
75. Drop Illustrated by Test Casting 83 Th fir t L I in uring any defect permanently is to call a meet-
76. Sticker Due to loose Pins and Bushings 85 illg of P r ons familiar with the various foundry operations related
77. Sticker Resulting from Wet Sand 86 ro th production of the castings in question. Using "Analysis of
Castings Defects" as a guide, these men can study the defective
78. Sticker Caused by Hard Ramming 86
rnstings, consider over-all conditions and establish the basic causes.
79. Rodgh Surface Due to Coarse Seacoal 88 /\ ppropriate steps can then be taken to modify production methods
80. Penetration Due to Overheating of Core 91 and materials to correct the defect.
81. Fused Sand Remaining after Dissolving Iron ovt of Penetrated Core 91 A prime mistake in curing defects is the tendency to criticise
and condemn persons involved in the operation. This should be
82. Penetration in a Soft Core 92
replaced with praise for finding and permanently correcting the
83. Penetration Should Not Be Confused with a Scab 93 ondition which caused the defect.
84. Polished Section Showing Penetration 93 The Outline of Causes of Gray Iron Casting Defects on page xii
85. Shift Due to Poor Pattern Alignment 98 Ii ts thirty-one defects attributable to ten specific and one general
phase of foundry operation. This outline-a summary of the de-
86. Shift Caused by Reversing Cope 99
tailed causes listed in the book-can be used advantageously to
87. Shifts Caused by Improper Handling of Jackets 99 get an over-all picture of the probable cause of any defect.
88. Core Raise of Green Sand Core 101 It is interesting to note that pouring practice is the cause of the
89. Core Raise Due to lack of Chaplets 102 greatest number of defects, with molding practice a close second.
In contrast, the fewest defects are attributable to metal composi-
90. Ramoff Due to Careless Ramming 104
tion and melting practice. Scars, shrinks, hard spots, open grain,
91. Defective Casting Not Completely Cored 106 misruns and blows can be caused by most of the fundamental
92. Omission of Core in Mold 106 Ihases of foundry practice and can be expected to occur most fre-
93. Typical Runouts 109 quently.
94. In this book, each defect is described, illustrated and analyzed
Runoutswhich Emptied Much o(the Mold Cavity 110
as to causes. Many times a defect results, not from a single factor,
95. Bleeder Caused by Early Shakeout 111 but from several. Most frequent causes of casting defects have
96. Effects of a Damp ladle 114 been marked with an asterisk-*.
97. Inverse Chill and Centerline Shrinkage. 115 Numbers following specific causes of defective castings indicate
98. the figures which illustrate the defect resulting from these causes.
Inverse Chill in a Square Section 115
he defect pictures have been gathered from foundries through-
99. Cylinder Head Poured Short 116 out North America. In some cases the donors wish to remain
/ 100. Casting Poured Short 116 anonymous, so for the sake of uniformity, no mention is made of
101. Kish in Casting Poured Too Cold 117 ontributors.
Without assistance from many Ioundrymen, the data will re-
main incomplete; therefore, in order to publish better volumes in
the future, pictures of casting defects and suggestions for making
(I book more useful to foundrymen are solicited. These should be
s nt to American Foundrymen's Association, 222 'West Adams St.,
hicago 6.
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FACTORS CAUSING 10 11 6 7 11 6 11 11 8 11 8 6 ~
EACH DEFECT
'~'

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 ''1 I , 11,,1,

nlow 01' (:11 1101." Blow (II /-Ill 111I1(' :11'(' l'Olllld('d nvi t ies,
, IIIPI plH'lj( r l, 1I:,II('ll('d, 01 dOIl/o\:llt'd, whit It arc auscd I y rb
W'IH'I.!ljOII :llld/ol' :1C'C'llllllti:tlioll of gas or (;Illrapp d air, Th y
III ill si/,(' (lV('I':t wide I':tng 'and th 'walls may vary in color from
dill k 1>111(' 10;1 silvery Jllcl"lli IU'l L Blowhol s caused by trapped
11I11>1>1('s or gas ill 111' 111 tal rarely oc ur on the drag surfaces of a
( ,I,~Iillg'. 'L'1t 'y ma Y 0 ur a a rnooth depression on the sides or
(Opt', I' a' a s rie of jagged, irregular depressions on the cope,
ADO.~u' ',' ,,-u.• LT ('Spt· ially on flat surface.
Foundry Department, Cor blows generally show on or near the surfaces of the cored
TH'S ROAD, MOUNT_All. r nviry. Blows caused by chills, chaplets, or wires are found as one
""AO~Ag-a /II' more gas pockets adjacent to these inserts.
'Porosity caused by steam or gas passing through the metal,
whi h may be accompanied by inclusions of dirt or dross (mold
1:1 '), is a blow. Such porosity may resemble a shrink or dendritic
II' 'a and frequently is mistaken for a shrink.
Pin Holes. A portion of the casting, or sometimes the entire
surface, may be pitted with small holes about the size of a pin
point. A pin hole may be a surface indication of a subsurface blow
Ito] .

Blisters. A shallow blow with a thin film of iron over it appear-

ing on the surface of the casting.

Causes
A. Due to Design
1. Insufficient print or outlet provided for venting
B. Due to Pattern Equipment- one
Due to Flask Equipment and Rigging
1. Bars in flask too close to mold surface
*2. Cope too shallow
D. Due to Gating and Risering
1. Head pressure too low due to insufficient sprue height
or shallow runner box
2, Head pressure too low as a result of gates freezing too
soon (long and thin gates)-Fig. I
jf<E. Due to Sand
1. Too high moisture-Fig. 2, 3,4,5
2. Too low permeability
a. Too high fines-Fig. 4
b. Too low grain fineness and poor grain distribution

• Major cause of defect.

, .
I
,...••.
'..•~
2 Analysis of Casting Defects Blows: Gas Holes, Pin Holes, Porosity and Blisters 3
. !
3. Too high green strength 2. Insufficient venting in either green or dry sand mold
4. Too high lime content 3. Vent from core to outside smaller than vent in core
5. Too much carbonaceous or gas producing material 4. Insufficiently dried molds
6. Foreign material inclusions such as shot iron, nails, *5. Hard ramming causing mold hardness to be too high
coke, etc.-Fig. 6 and permeability too low=Fig. 16,17,18
7. Concentrated clay balls 6. Ramming non-uniform and' too close to pattern
8. Poorly mixed sand 7. Gaggers or soldiers too close to the pattern
8. Clay wash too heavy on gaggers
9. Excessive slicking and patching in green sand
F. Due to Cores
*1. Hard cores or hard spots in the core-Fig. 10. Wet clay at parting line .
7, 8,9, 10, II,
II. Too hard or wet pouring dish
12
12. Mold wash or coating material too heavy or not dried
*2. Low permeability in core-Fig. 9, l O, II
*3. Underbaked cores
4. Improper venting in the cores-Fig. 5, 14
a. Vents too near the surface B. Due to Metal Composition
b. Insufficient number, too small, or too large-Fig. 9, I. The presence of certain metallic impurities such as alu-
io, 11 minum, antimony, tin, etc.-Fig. 21, 22
c. Not properly protected
d. Permeability of core too high in comparison with
the amount of venting
*1. Due to Melting Practice
e. Vents closed off in pasting
£. Vents not connected I. Cold or sluggish iron-Fig. 19
5. Iron getting into the vents
2. Oxidized or gassy iron caused by:
a. Too Iowa bed
6. Core paste causing the iron to boil; too much or too
b. 'Net and hard rammed bottom
wet paste
c. Insufficient slag volume (blast oxidizes metal in well)
7. Core wash or coating too heavy and/or not dry
d. Excess air causing loss of fluidity or gassy iron (caused
8. Too much carbonaceous or gas producing material
by improper balance in the cupola between blast and
either in the core sand or wash
9. Cores absorbing moisture, either in storage or in mold coke)
e. 'Wet spout
10. Exposed hooks or hangers
II. Joint sealing material not dried
12. Exposed core wire .
13. Hook or hanger holes filled arid not dried
*J. Due to Pouring .
14. Too high lime in core sand
I. Cold, damp, or green ladles (lips andlining)-Fig.'20
IS. Foreign materials such as roots, leaves, coke, coal
2. Pouring cold metal-Fig. 21
16. Concentrated balls of clay, cereal, etc.
17. Poorly mixed core sand
K. Due to Miscellaneous
G. Due to Molding Practice 1. Due to Chills, Chaplets and Wires
* 1. Any combination of hot and cold materials a. Chill too cold
a. Hot flasks and cold sand b. Ru ty hills, haplct or wires
b. Hot sand and cold flasks c. Iniprop Tly oat d chilL chap] or wir ·-Fig.23
c. Hot san 1 and cold core-Fig. IS d. Damp chills chapters or wires
d. ) 101 r and old, and ('. Pill('d 01' cheri ('<1chills which \'('I:till moisture
4 Analysis of Casting Defects, Blows: Gas Holes, Pin Holes, Porosity and Blisters 5

Fig. 1-/mproper gating, wet sand, hard ramming and ineffective pop-offs contributed to these
blows.

II J /'In hol s caused by excessive moisture in sand bonded with western bentonite. The sand
h'll/,III If rain distribution (over 6 sieves), permeability 140, compressive strength 10.5 psi and
moisture content of 4.5 %.
 6 A.nalysis 01 Casting D@I@cts Blows: Gas Holes, Pin Holes, Porosity and Blisters 7

111/.I/-Blow caused by high moisture and low permeability. This defect was incorrectly called a
. pull down and a shrink.
"~ S-Pln holes resulting from excessive permeability and moisture. remedied by lowering the
permeability from 140 to 90-11.0, reducing moisture from 4.2% to 2.8%.

Fig. 3-Blow on the cope side of pump impellers caused by wet sand and hard ramming. Upper
view shows drag side.
8 A ••a'Yllill 01 Calltin.g I!electll Blows: Gas Holes, Pin Holes, Porosity and Blisters 9

I'll I Blow caused by a ha;d ram- up core at a hot spot in a manifold. Cured by using less bind-
Fig. 6-Blow caused by foreign maffer in fhe molding sand. ing materials in the core.
Fig. 8-Enlarged view of defect shown in Fig. 7.
10 Analysis 01 Casting Belects Blows: Gas Holes, Pin Holes, Porosity and Blisters 11

Fig. 9-Blow in Diesel engine head caused by excessive gas and subsequent boiling of the metal
which eroded lower [acke] core.

Fig. IO-Diesel engine head blow magnified 3 times.

12 Analysis 01 Casting Delects Blows: Gas Holes, Pin Holes, Porosity and Blisters 13

Fig. 12-Blow caused by hard core and insufficient venting. The cavity has the appearance of a
shrink which is the result of gas agitation just before solidification.

Fig. 13-Blow on the cope side caused by the formation of excessive gas at a hot spot on the
core. Venting of core and reduction of binder prevented the defect.

/11/. 1"-Casting sectioned two

,ty 10 show blow hole in cored
",v/ly. The apparently small de-
/ .1 which appears as a small black
'Jilil III th core cavity at the right
(ld,IlV.) is shown On further see-
1/11/11/11 (b low) to be a com para-
I/vHly lorg blow hole. Defect
,1//1111 hy faking vent off the core.
 14 Anolysis 01 Costing Delects Blows: Gas Holes, Pin Holes, Porosity and Blisters 15

Fig. 1S-Blow caused by moisture from hot molding sand condensing on cold core surface. Room
o
temperature was 6S F. The molding sand had a temperature of 1360 F., permeability of 120,
green compression strength of 11 psi, and moisture content of 3.5%. The mold stood 80 minutes
before pouring. After cooling, the casting was cleaned and machined, the holes on the cope
surface appearing during machining. The cylinder sleeve, 4 inches /D, cast on its side, was gated
at both ends.

Fig. 17-Blister on a sanitary casting caused by hard ramming and wet sand.

Fig. 18-81i.1 r cau. d by hard ramming as il appoars after cleaning.

Flo. 16 Blow dill 10 axel' lv» III I tur III Ih ond (4.5%) and IInn~ .My r mm/l/O olllblll d
wllh III 1111I I III I' rill ahl/lly (90). Allh lIuh II I fI nail tI tI h,IIIA, /I I /I '" rill Ih
h ,I I. /I Ih t/ll/l1.11/ tlml / lid. III vunl,
 16 A.nalysis of Casting Defects Blows: Gas Holes, Pin Holes, Porosity and Blisters 17

1/1/. 21-Pin holes found during machining resulted from the presence of aluminum and other
non-ferrous metals.

I II· 22-Blow holes caused by die casting machine "goose neck" filled with alloy, accidentally
entering the charges and contaminating the metal.

Fig. 19-Blows caused by cold metal. The smooth rather than dendritic surface conclusively proves
thai this is not a shrink but a blow due to gas frapped in the rapidly solidifying cold metal.

Fig. 20-Gas holes caused by green

or damp pouring ladle.
18 Ano'ysis of Costing Defects

Scars. Sea",s and Plates

Scars are generally found on a flat surface where entrapped gas

has prevented the mold cavity from being filled completely.
Plates are formed when metal oozes-into a scar.
A seam is a surface defect related to but of lesser degree than a
coldshut.
Causes
A. Due to Design
1. on-uniform casting sections resulting in interrupted
metal flow

B. Due to Pattern Equipment

1. Worn patterns or core boxes causing thin metal sections
2. Patterns not made according to blueprint being too thin
3. Patterns not properly reinforced

Due to Flask Equipment and Rigging

1. Cope and drag shift causing thin metal sections
2. Patterns not properly mounted
3. Lack of tilting arrangement for thin flat surface
Fig. 23-Upper section shows chaplet blow caused by improper coating materials or a damp 4. Flask insufficiently barred allowing cope to sag
chaplet. Lower section shows good fusion.
I. Due to Gating and Risering
1. Improperly gated .
a. Gates so located that converging streams of metal
promote a gas trap
b. Insufficient number of gates
c. .al not properly spaced
d. Too I w h ad pressure

1)11(' 10 Salld
I. Back PI' 'sur cau ed by too low permeability due to
San It 0 high in fines
~I.
b. Too low grain fineness and poor grain distribution
~. Too high in moisture-Fig. 26, 27
II. Too high in gas forming materials
~. Weak backing and causing cope to sag

F. 1)11(' 10 Cores
I. COI'(' 100 low in P rrncabiliry due to
:1. Too high in fin s
II. '/'00 low grain rillen iss ~1I1c1 poor grain di tribution
1/ l usull« il'lll VI'1I1 illg'
,I. Too IIIIU II (\:1 II 111:11"1 in l
-I. (!Oll' Inilltitid II" "( tiOIlS illvo",'d
20 Analysis of Casting Defects Scars, Seams and Plates 21
5. Cores not properly sized or fitted, allowing decreased
metal section K. Due to Miscellaneous
1. Chills and chaplets too cold
6. Excess blacking 01: paste on core causing thin metal sec-
2. Improperly coated chills or chaplet~ .
tion
3. Condensation in mold cavity on thin section work
7. Raised or sagged cores
8. Core shift causing thin metal sections

G. Due to Molding Practice

1. Hard ramming-Fig. 26, 27
2. Improper venting
3. Too low head pressure
4. Hard ramming causing low permeability which de-
velops excessive back pressure in the mold-Fig. 24, 25
5. Uneven ramming
6. Soft ramming allowing cope to sag and cause thin metal
section
7. Mold insufficiently gaggered, allowing the cope to sag
8. Improperly bedded. bottom boards causing gates or
other sections to be partially clamped shut
9. Excessive slicking and patching
10. Thin flat surface molds set level instead of tilting
11. Wrong dimension chaplet used, allowing thin section
12. Too light chaplet used allowing chaplet to burn out

H. Due to Metal Composition

1. Iron not fluid enough due to composition
a. Too high or too low carbon equivalent for the mold
conditions involved
b. Excessive carbide stabilizers
c. Excessive graphitizers

I. Due to Melting Practice

1. Wrong composition due to careless weighing or charg-
ing
2. Cold melted or sluggish iron
3. Oxidized or gassy iron
4. Over reduced iron
5. Excessive ladle additions

J. Due to Pouring
1. Pouring temperature too low
2. Interrupted pouring
3. Slackening rate of pouring too Don
4. Boiling iron from any aus
.5. hin flat surf'n s I ourcd On t hc 1'v('1
n. F., {'s~iv(' w('ighlill
l or IllolcJH
7. Prnu illg )II (' ,111'(' ,,'dll!'!-" h 111110111
22 Analysis 01 Cas~ing lJelec~s
Scars, Seams and Plates 23

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 Shot .lroll, or Cold Shots Shrin"age Cavities and Depressio ••s
Shot iron or cold shots are small globules of metal embedded in, A shrinkage cavity or depression, large or small, results from
but not entirely fused with, the casting. In many cases, shot iron varying rates of contraction while the metal is changing from
may be caused by a blowing action somewhere in the mold cavity liquid to solid. A true shrinkage defect is generally a jagged hole
and although the blowing action may cease and the metal sections or spongy area lined with fernlike crystals called dendrites. These
become sound yet the shot iron may remain. true shrinkage defects must be differentiated from hot tears and
cracks. A shrinkage depression on the surface of a casting is a re-
Causes cession from the true plane of the mold surface.

A. Due to Design- one Causes

B. Due to Pattern Equipment
A. Due to Design
1. Core print too small allowing too much fin. Metal
l. Change in section size too abrupt
striking clay roll and blowing
2. Isolated heavy sections which cannot be fed
c. Due to Flask Equipment and Rigging-None 3. Insufficient fillets
*D. Due to Gating and Risering 4. Too heavy a fillet
1. Gate permitting the metal to spatter or spray B. Due to Pattern Equipment
2. Shot tower effect from skimmer core due to insufficient 1. Improper fillets
basin at bottom of sprue 2. Insufficient head due to shallow cope flask
3. Pop gates not forming pool of metal for cushion fast 3. Insufficient or no provision for feeding heavy section
enough
*E. C, Due to Flask Equipment and Rigging
Due to Sand-(Only if it creates a blowing action)
1. Too high moisture causing boiling action 1. Cope flasks too shallow
2. Too low permeability due to ·D. Due to Gating and Risering
a. Too much fines
1. Gates and risers not promoting progressive solidifica-
b. Too low grain fineness or poor distribution
tion-Fig. 28, 29
3. Improper conditioning of sand permitting tramp iron,
2. Insufficient or improperly attached gates or risers-Fig.
wood, nails, inclusions, ete.
30, 31, 32, 33, 34
F. Due to Cores-(Only if it creates a blowing action) 3. Risers not large enough-Fig. 30, 31
1. Wet cores 4. Excessively large gates or risers
2. Iron in vent due to improper venting
3. "Wet core paste .. E. Due to Sand-None

G. Due to Molding Practice-(Only if it creates a blowing F. Due to Cores-None

action) G. Due to Molding Practice-None
1. Vents unintentionally sealed off *11. 1 LL ~o Metal Composition
2. Not enough or not large enough vents
I. 11 mical composition unsuited for section involved-
H. Due to Iron Composition=None Fi,g.35
1. Due to Melting Practice-None :1. Sili n.. arbon ratio out of balance-Fig. 28
J. Due to Pouring b. mbin d carbon too high
1. Careless skimming and pouring r. Phosph ru too high for application-Fig. 36
2. Intermittent pouring o d. Ovcr-ino ulat d with graphitizcrs
3. Cold iron t', lloy r.u io 1I1lSUil d for sc .ti n:
K. Du I Mise .llancou: - on I. Too IIi ,II ill nlll)id" ~lai>iliz('l's

1111111 111111' III iI.I.,. I

26 Analysis of Casting Defects Shrinkage Cavities and Depressions 27

1. Due to Melting Practice

1. Careless charging or weighing giving wrong composi-
tion

J. Due to Pouring
1. Pouring too cold permitting risers to freeze and not feed
2. Pouring too hot without adequate feeding provisions
3. Improper touch up of risers with hot metal

K. Due to Miscellaneous-None

:E
'"E
""0

..•..'"'"
..•..
o
""'u"
~

Fig. 28-T rue shrink (porosify) caused by lack 01 1 d m fal.