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Vineeta Kanwal ID NO - 44316
Classification of defects
Defects caused by patterns and moulding box equipment. Defects due to improper moulding and core-making materials. Defects due to improper sand mixing and distribution. Defects caused by moulding, core making, gating etc. Defects due to improper mould drying and core baking. Defects occurring while closing and pouring the moulds. Defects caused by molten metal. Defects occurring during fettling etc. Defects due to faulty heat treatment. Defects due to cast metal. Warpage.
Crush
Displacement of sand while closing a mould Irregular sandy depression in the casting Coreprint with too little clearance Excessive weight of cope portion
Blowholes
Smooth and round holes Location always in the upper part of the castings and beneath cores or undercuts Occur due excessive moisture, presence of gas producing ingredients, inadequate venting and low permeability of the mould
Drop
Occurs when cope surface cracks and breaks Due to low green strength Low mould hardness Insufficient reinforcement of sand projections in the cope
Scab
Rough, irregular projections on surface of castings containing embedded sand Occurs when a portion of the face of a mould or core lifts and metal flows underneath in a thin layer Caused by using too fine sand grains or using sand of low permeability or moisture content or uneven mould ramming or by intense local overheating
Pin-holes
Small holes revealed on the surface of a casting after the surface has been cleaned by shot blasting Due to sand with high moisture content, faulty metal Gas dissolved in alloy and not being properly degassed
Hot tears
Ragged irregular internal or external cracks occurring immediately after the metal have solidified Due to poor collapsibility of cores, too much shrinkage of metal while solidifying High sulphur content Too low pouring temperature
Slag holes
Smooth depressions on the surface of castings Usually occur near the ingates Due to slag that enters in mould cavity Slag traps should be inserted in the gating system
Shrinkage defects
Caused by improper directional solidifications, poor gating and risering design and inadequate feeding Solidification leads to volumetric contraction which must be compensated by feeding Surface shrinkage or internal shrinkage defects are produced making the casting weaker
Run out
During the casting, metal runs out of the box at the parting Casting is incomplete or fully missing The upper part of a casting is mostly missing Due to faulty moulding
Inclusions
Foreign materials present in the cast metal. In the form of oxides, slag, dirt, sand or nails. Sand cracked and broken from gating system, mould cavity, cores etc Reduced by using correct grade of moulding sand and proper skimming to remove impurities.
Fusion
Thin sand crusts firmly adhere to the casting Rough cast surface Sand sintered on the casting, which can only be removed by grinding Using sand of enough refractoriness and pouring at suitable temperature can eliminate this defect.
Shot metal
Shots embedded in the casting Excessive sulphur content in the molten metal Higher moisture content of the moulding sand Faulty gating system Improper pouring of molten metal
Swells
Enlargement or bulging of the casting surface resulting from liquid metal pressure. Due to poor ramming of the mould or not properly reinforcing deep moulds. Avoided by proper ramming of the sand and providing adequate support to the mould.
Warpage
Surface of mould part do not follow the intended shape of the design. Results from residual stresses, caused by differential solidification rates
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