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Casting Quality and Defects

Manufacturing Process

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5 views

Casting Quality and Defects

Manufacturing Process

Uploaded by

muhammadahmed111118
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Casting Quality and Defects

Casting Quality

Casting quality refers to the overall integrity and performance of a casting, which includes its

dimensional accuracy, surface finish, mechanical properties, and the absence of defects.

High-quality castings meet the design specifications and are essential for the performance and

reliability of the final product.

Common Casting Defects:

Common Casting Defects:

1. Misrun

Definition: A misrun occurs when the molten metal does not fill the mold cavity completely, resulting

in an incomplete casting. Causes: Insufficient pouring temperature or inadequate pouring speed.

2. Cold Shut

Definition: A cold shut is a defect where two streams of molten metal meet but do not fuse properly,

creating a weak joint in the casting. Causes: Low pouring temperature or too fast pouring speed.

3. Cold Shot

Definition: Cold shots are small unmelted particles of metal that become trapped in the casting,

leading to weaknesses. Causes: Inadequate melting or premature pouring of the metal.

4. Shrinkage

Definition: Shrinkage refers to the reduction in volume of the casting as it cools, which can lead to

voids or cavities. Causes: Poor design, inadequate feeding, or cooling rates.

5. Microporosity

Definition: Microporosity is the presence of tiny pores within the metal that can affect its mechanical

properties. Causes: Solidification shrinkage or gas entrapment during pouring.


6. Hot Tearing

Definition: Hot tearing occurs when the casting cracks during solidification due to thermal stresses.

Causes: Insufficient strength of the metal during the cooling process.

7. Sand Blow

Definition: Sand blow is a defect caused by the expansion of gases during pouring, resulting in a

raised area on the surface of the casting. Causes: Poor mold permeability or excessive moisture in

the sand.

8. Pinhole

Definition: Pinhole defects are small holes in the surface of the casting, typically caused by trapped

gases. Causes: Insufficient venting or excessive gas in the molten metal.

9. Sand Wash

Definition: Sand wash occurs when the molten metal erodes the mold surface, leading to rough

areas on the casting. Causes: High pouring temperatures or insufficient mold strength.

10. Scabs

Definition: Scabs are raised defects on the surface of a casting caused by sand or other

contaminants. Causes: Poor mold preparation or contamination.

11. Penetration

Definition: Penetration refers to the molten metal seeping into the sand mold, creating a rough

surface finish. Causes: Low mold strength or excessive pouring temperature.

12. Mold Shift

Definition: Mold shift occurs when the two halves of a mold misalign, leading to defects in the

casting. Causes: Poor mold alignment or mechanical failure.

13. Core Shift

Definition: Core shift is similar to mold shift but specifically refers to the misalignment of core

components, affecting internal features. Causes: Improper core support or alignment.


14. Mold Crack

Definition: Mold cracks are fractures in the mold material that can lead to defects in the casting.

Causes: Thermal stress or mechanical shock during the pouring process.

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