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Types of Casting Defects: Admin November 23, 2017 Casting Defect1

This document discusses common types of casting defects including burn on defects, broken mould defects, lustrous carbon inclusions, pin holes, scabs, roughness, blow holes, and slag inclusions. For each defect, it provides the nature of the defect and potential remedies such as increasing or decreasing certain sand components, changing casting temperatures, or improving mould permeability. The goal is to identify causes and solutions for common defects that can occur during the metal casting process.

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Nasir Soudagar
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201 views5 pages

Types of Casting Defects: Admin November 23, 2017 Casting Defect1

This document discusses common types of casting defects including burn on defects, broken mould defects, lustrous carbon inclusions, pin holes, scabs, roughness, blow holes, and slag inclusions. For each defect, it provides the nature of the defect and potential remedies such as increasing or decreasing certain sand components, changing casting temperatures, or improving mould permeability. The goal is to identify causes and solutions for common defects that can occur during the metal casting process.

Uploaded by

Nasir Soudagar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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TYPES OF CASTING DEFECTS

admin November 23, 2017 Casting Defect1

BURN ON DEFECT
Nature of Defect : Thin sand crusts firmly adhering to the casting. Defect occurs more
frequently with thick walled castings at high casting temperature.
Remedies : Increase amount of lustrous carbon producers and coke producers in the molding
sand. Increase amount of new sand if sintering point of the sand is low and oolitization is high.
BROKEN MOULD DEFECT
Nature of Defect : Flash-like metal penetration in the mould, sometimes parts of the mould are
included in the casting.

Remedies : Add more bentonite to increase green tensile strength.Raise compactability of the
moulding sand.

Lustrous Carbon Inclusions Defect


Nature of Defect :Formation of surface irregularities, inclusions and laps due to non-wetting
characteristic of lustrous carbon, often associated with the use of Cold-Box cores.

Remedies : Use dried Cold-Box cores.Reduce amount of lustrous carbon producer in


the moulding sand. Use carbon-aceous additive with a higher coking residue.
Pin Hole Defect
Nature of Defect : Accumulation of small sub-surface rounded holes.Defects appear after
annealing and light machining.

Remedies : Normally the defect is of a metallurgical nature.The mould material may have a
certain effect. In case of pin holes the moisture, the organic additions and the amount of nitrogen
in the moulding sand should be reduced.

Scab Defect
Nature of Defect : Mushroom type defect with sharp edges parallel to the casting surface.

Remedies : Increase bentonite level. Use carbonaceous additive with a wide softening range.
Increase the amount of carbonaceous additive in the moulding sand.
Roughness
Nature of Defect : Rough casting surface finish due to coarse sand.

Remedies : Use finer sand. Increase amount of lustrous carbon producing material in the
moulding sand. Increase the amount of fines e.g. coke in the sand.

Blow Hole Defect

Nature of Defect : Cavities with smooth walls,singularly or in groups.

Remedies : Low casting temperatures are often the cause. Benefits may be obtained by
increasing mould permeability. Reduce fines or add coarser new sand. Reduce organic additions
to the sand.
Slag Inclusion Defect
Nature of Defect : Non-metallic irregular shaped inclusions, when occurring,tend to be on upper
casting surfaces.

Remedies : The defects are caused by slag being present with the molten metal in the pouring
ladle. If the formation is due to eroded sand, reduce the amount of inert fines and use a more
active lustrous carbon producer. Increase milling time of the moulding sand

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