Casting Discontinuities
K.N.Karn,CDM,BARC,Mumbai
Casting
Casting is a product obtained by pouring the
molten metal in a cavity called mould and
allowed to solidify to get the desired shape
and size.
Sand casting
Permanent Mould Casting
Die Casting
Centrifugal Casting
Investment Casting
K.N.Karn,CDM,BARC,Mumbai
K.N.Karn,CDM,BARC,Mumbai
K.N.Karn,CDM,BARC,Mumbai
Origin of defects
The casting design
The technique of manufacture
Workmanship
Shaping faults arising in pouring
Inclusion and sand defects
Gas defects
Shrinkage defects due to volume contraction
in liquid state during solidification
K.N.Karn,CDM,BARC,Mumbai
Casting Discontinuities
Surface roughness: Too coarse a moulding Sand,
Pouring temperature too high, surface reaction.
Scabs or buckles: Due to some sand shearing from
the cope surface and making a metal layer
separated from the casting by a layer of sand.
Blow Holes: Internal voids produced by excessive
gaseous material that could not escape.
Sand Spots: Impurities collected at one or more
locations.
K.N.Karn,CDM,BARC,Mumbai
Swells: Swelling of casting resulting from
enlargement of mould cavity when molten
metal is poured.
Shrinkage: Contraction of the metal during
solidification
Hot tears: Hindered contraction occurring
just after solidification.
Cold cracks: Hydrogen induced cracks in
highly stressed casting.
K.N.Karn,CDM,BARC,Mumbai
Cold shorts: Too streams of metals that are too
cold to fuse properly, slow pouring.
Lifts and shifts: Misalignment of pattern parts.
Sponginess or Honey Combing: A number of
cavities in close proximities, open to surface,
because of dirt in molten metal
Pour Shorts: Incomplete filling of the mould
Gas Porosities: Rounded voids due to gas
dissolved in molten metal.
Run outs and Bust outs: Drainage of metal from
cavity, gives incomplete casting.
K.N.Karn,CDM,BARC,Mumbai
Metal Penetrations: Penetration of metal in
the interstices of sand grains, fused
aggregate of metal and sand.
Fins: A thin projection of metal not intended
as apart of casting
Misruns: Improper filled corners and mould
cavities, low poring temperature.
Dimensional error: Variation in size
Compositional error and segregation:
Variation in chemical composition of the
casting metal.
K.N.Karn,CDM,BARC,Mumbai
K.N.Karn,CDM,BARC,Mumbai
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Cold shuts
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Cold shuts
Cold shuts
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Shrinkage cavity
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Forging Discontinuities
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Forging
Controlled plastic deformation of metals at
elevated temperature into pre determined
size or shape using compressive forces
exerted through some type of die by a
hammer, a press or a upsetting machine,
rolling and extrusion etc.
Forgings have high strength and ductility
and offer greater resistance to impact and
fatigue loads due to extra working during
the process and the opportunity of aligning
the grain flow.
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Because of intense working flaws are
seldom found in forging and components
have high reliability.
Almost all metals can be forged, but the
metals which has low yield point can be
forged with ease.
Materials like Aluminium, Copper and their
alloys, steels, Titanium and many other also
can be forged.
High initial costs, rapid oxidation of die
surface.
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Forging Discontinuities
Mismatch
Scale pits
Unfilled sections
Defects resulting from improper heating
and cooling of the forging such as burnt
metal, decarburised steel and flakes
Dirt , slag and blow holes
Ingot defects, pipes, cracks, scabes,
segregation
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Seams
Cold cracks
Laps
Cold shuts
Wrinkles
Overlaps
Distortion
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