A STUDY OF QUALITY CONTROL OF CASTING

PRODUCT

A DISSERTATION
SUBMITTED IN PARTIAL FULFILLMENT OF REQUIREMENTS FOR THE AWARD OF
THE DEGREE OF

MASTER OF TECHNOLOGY
IN
MANUFACTURING & AUTOMATION
BY
ARYA NAVNITA

(UNIV. ROLL NO. 4699421)

UNDER THE GUIDANCE OF

ER. HARI PRASAD

(Assistant Professor, M.E Dept., SET, SOLDHA)

DEPARTMENT OF MECHANICAL ENGINEERING

SCHOOL OF ENGINEERING & TECHNOLOGY

M.D. UNIVERSITY ROHTAK, HARYANA (INDIA)

(JUNE-2017)
 ACKNOWLEDGEMENT

I am highly grateful to the Honble Vice-Chancellor, M.D. University for providing me

this opportunity to carry out the present dissertation work.

The constant guidance and encouragement received from Er. Hari Prasad, the Head of the
Mechanical Engineering Dept. of School of Engineering & Technology, Soldha, Bahadurgarh
has been of great help in carrying out the present work and is acknowledged with reverential
thanks.

I would like to express a deep sense of gratitude and thanks profusely to my Dissertation
Supervisor, Er. Hari Prasad, Assistant Professor, Dept. of Mechanical Engineering of School
Engineering &Technology, Soldha, Bahadurgarh. Without his wise counsel and able guidance, it
would have been impossible to complete the dissertation in this manner.

The help rendered by Dr. Rakesh Rajpal, Director, School of Engineering & Technology,
Soldha, Bahadurgarh for experimentation / simulations is greatly acknowledged. I also express
my gratitude to other faculty members of Dept. of Mechanical Engineering of School of
Engineering & Technology, Soldha, Bahadurgarh for their intellectual support throughout the
course of this work.

It gives me great pleasure to acknowledge the support and help of Mr. Vishant Guliya
and Mr. Rajesh Kumar for their help throughout my research work.

So many people have contributed to my research work, and it is great pleasure to take the
opportunity to thank them. I apologize, if I have forgotten anyone.

ARYA NAVNITA
Regn. No.- 1513670180
Univ. Roll No.- 4699421
 CERTIFICATE

This is to certify that the project titled Casting Defects,Causes And Their Remedies
submitted by Arya Navnita to School of Engg. & Technology, Soldha, Bahadurgarh for
the award of degree in M. Tech. in Manufacturing & Automation is a record of bonafide
work carried by him under my supervision. In my opinion, project has reached the
standards of fulfilling the requirements of regulations to degree. The work contained in
this project has not been submitted to any other university/Institute for the award of any
degree or diploma.

Er. Hari Prasad

Assistant Professor

Department of ME

SET, Soldha

Er. Hari Prasad Dr. Rakesh Rajpal

HOD DIRECTOR
Department of ME SET, SOLDHA
SET, SOLDHA
 CANDIDATES DECLARATION

I hereby certify that the work which is being presented in this project titled
Casting Defects,Causes And Their Remedies in the partial fulfillment of the requirement for
the degree of M. Tech. in Manufacturing & Automation submitted to School of Engg. &
Technology, Soldha, Bahadurgarh is an authentic record of my own work carried out under
supervision of ER. HARI PRASAD. The matter presented in this report has not been submitted
by me for the award of any other.

Arya Navnita

Regn. no.- 1513670180

Univ. Roll No.- 4699421

This is to certify that the above statement made by the candidate is correct to the best of my
knowledge & belief.

Signature of Supervisor

Er. Hari Prasad

Assistant Professor

SET, Soldha (Bahadurgarh)

The M.Tech. Viva-Voce Examination of Ms. Arya Navnita has been held on............................

Signature of HOD Signature of External Examiner

iv
 ABSTRACT

Foundry industries in developing countries suffer from poor quality and

productivity due to involvement of number of process parameter. Even in completely
controlled process, defect in casting are observed and hence casting process is also known as
process of uncertainty which challenges explanation about the cause of casting defects.
In order to identify the casting defect and problem related to casting, the study is
aimed in the research work named as Casting Defects,Causes And Their Remedies. This
will be beneficial in enhancing the yield of casting. Beside this, standardization (optimization)
of process parameter for entire cycle of manufacturing of the critical part is intended in the
proposed work. This study aims to finding different defects in casting, analysis of defect and
providing their remedies with their causes. In this paper an attempt has been made to list
different types of casting defects and their root causes of occurrence. This paper also aims to
provide correct guideline to quality control department to find casting defects and will help
them to analyze defects which are not desired.
 CONTENT
PAGE NO.

Acknowledgement ii

Certificate iii

Candidates Declaration iv

Abstract v

List of Figures ix

Chapter.1 INTRODUCTION

1. Casting
1
1.1 Types Of Casting 3

1.2 Expendable mold casting 4

1.2.1 Sand casting 4
1.2.2 Plaster mould casting 4
1.2.3 Shell Moulding 4
1.2.4 Investment casting 4
1.2.5 Waste Moulding of plaster 5
1.2.6 Evaporative-pattern casting 5
1.2.6a Lost-foam casting 6
1.2.6b Full-mould casting 6

1.3 Non-expendable mold casting

1.3.1 Permanent mould casting 6

1.3.2 Die casting 6
1.3.3 Semi-solid metal casting 6
 1.3.4 Centrifugal casting 6
1.3.5 Continuous casting 7
1.3.6 C
Non-expendable mold casting 7

O
N
Chapter 2 LITERATURE REVIEW 8
TAnd Their Remedies
Chapter 3 Casting Defects, Causes 11
E
3.1 Casting Defects N
3.1.1a T
Blowhole 11

3.1.1b Sand S
Burning 12

3.1.1c Sand Inclusion 22

3.1.
3.1.1d Cold Lap Or Cold Shut 22
1.e
Misrun 23
3.1.1f Gas Porosity 23

3.1.2 Shape Defects 24

3.1.2a Mismatch Defect 24

3.1.2b Distortion Or Warp 24
3.1.2c Flash Defects 25

3.1.3 Thermal Defects 26

3.1.3a Crack Or Tears 26

3.1.3b Shrinkage 27
3.1.3c Sink Mark 28

3.1.4 Defects by Appearance 29

3.1.4a Metallic Projection 29

3.1.4b Cavities 29
3.1.4c Discontinuities 30
3.1.4d Incomplete Casting 30
 3.1.4e Incorrect Dimension or Shape 31
3.1.4f Defective Surface 31
3.1.4g Rat Tails And Buckles 32

Chapter 4 CONCLUSION AND FUTURE SCOPE 33

REFERENCES 34
 LIST OF FIGURES

Figure Detail of Figures Page No.

Fig. 1.2.4 An Investment Cast-Valve Cover 5

Fig. 3.1.1aB Surface Defects 13

Fig. 3.1.1aD An Enlarge Picture 14 14

Fig 3.1.1aE Sub Surface Slag Reaction Hole 15

Fig 3.1.1aF Sub Surface Defect 15

Fig. 3.1.1aG Sub Surface Defect 16

Fig. 3.1.1aH Mould or Core Gases Defect (Steel) 16

Fig. 3.1.1aI Mould or Core Gases Defect 18

Fig. 3.1.1aJ Entrapped Air Defect(Steel) 18

Fig. 3.1.1aK Entrapped Air Defect 20

Fig 3.1.1aL Chaplet Defects 20

Fig. 3.1.1bA Sand Burning Defect 21

Fig. 3.1.1cA Sand Inclusion Defect 22

Fig. 3.1.1dA Cold Shut Defect 23

Fig. 3.1.1eA Misrun Defect 24

Fig, 3.1.1fA Gas Porosity Defect 25

Fig, 3.1.2aA Mismatch Defect 26

Fig. 3.1.2bA Distortion Defect 26

Fig. 3.1.2cA Flash Defect 26

Fig 3.1.3aA Crack Defect 27

Fig. 3.1.3bA Shrinkage Defect 28

Fig. 3.1.3cA Sink Mark 29

Fig. 3.1.4aA Metallic Projection 30

Fig. 3.1.4bA Blowhole 30

Fig. 3.1.4cA Body Cracks 31

Fig. 3.1.4dA Incomplete Casting 31

Fig. 3.1.4eA Distortion Defect 32

Fig. 3.1.4fA Defective Surface 32

Fig. 3.1.4gA Rat Tail Defect 33