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A faulty casting has arrived at your facilitys door. Youre not exactly sure whats
wrong with it, but from what youve heard, youre pretty sure its porosity.
You call your metalcaster. You tell the quality control manager youve got porosity.
She wants to know more.
Youre stumped.
What you have on your hands is a cavity-type defect. While many kinds of these
defects exist, most buyers and designers of castings know them only as porosity. If you
could just give the quality control manager a more specific defect name, shed know
its root cause and therefore how to fix it.
Defect:
Dispersed ShrinkageCharacteristic of
cast iron, these cavities are most often
perpendicular to the casting surface,
with depths as great as 0.8 in. (2 cm).
The casting defect is most commonly
caused in iron components by low
carbon content or high nitrogen
content in the melt.
3.One of your iron castings fractures and reveals smooth, slightly curved facets on the
fracture face.
Defect: Conchoidal or Rock Candy FractureThis defect is characterized by
separation along the grain boundaries of primary crystallization. The resulting
configuration is often compared to the appearance of rock candy. The defect is caused
in steel castings by elevated aluminum and nitrogen levels.
4.Your casting has smooth-walled, rounded cavities of various sizes clumped together
in one area.
Defect:
Blowholes/PinholesThe interior
walls of blowholes and pinholes can be
shiny, more or less oxidized or, in the
case of cast iron, covered with a thin
layer of graphite. The defects can
appear in any region of a casting. They
are caused when gas is trapped in the
metal during solidification.
Blowholes/Pinholes
5.Your iron casting has folded, shiny
films in its walls.
Defect: Lustrous CarbonThese folded or wrinkled films are distinctly outlined and
found within the walls of iron castings, causing a linear discontinuity in the structure.
Generally, they are seen only upon fracturing a casting. The defects form when
materials from mold or core additives and binders volatize, decompose and become
entrained in the melt.
9.Your casting is essentially complete except for more or less rounded edges and
corners.
Defect: MisrunThis defect can occur with the use of any casting alloy, but in the case
of iron, the surface is generally shiny and easily cleaned. The problem can come about
due to a lack of alloy fluidity, slow mold filling, inadequate venting of the mold and (in
permanent molding) low temperatures.
11.Your casting has been stored for some time, and when you pull it out for assembly,
you notice it has bent out of specification.
Defect: Warped CastingDistortion due to warpage can occur over time in a casting
that partially or completely liberates residual stresses. Common practice in iron casting
is normalizing heat treatment to remove residual stress. In aluminum casting, a
straightening between quench and aging might be required.
12.Your iron casting has branched grooves of various lengths with smooth bottoms and
edges.
Defect: BuckleOccurring in all ferrous alloys and sometimes in copper-base castings,
the defect is caused by the expansion of silica sand. The defect distinguishes itself
from a scab (see question 18) in that it does not allow penetration of the metal into
the adjacent cavity below.
13.Very small grooves (less than 0.5 in.) on the surface of your casting are almost
covered by a folded edge.
Defect: Rat TailThis shallow defect occurs in ferrous and nonferrous green sand
castings. Rat tails most often extend from the area where the metalcaster gates the
casting. Rat tails may be accompanied by other projection-like defects. Metalcasters
can alleviate this defect by altering their sand mixture.
14.Your iron casting has spherical particles coated with oxide inside it. The particles
are the same chemical composition as the base metal.
Defect: Cold Shot (Shot Metal)Not to be confused with a cold shut, this defect occurs
when small droplets of metal fall into a metalcasting mold, solidify and fail to remelt
when the remaining metal is introduced to the mold. The defect is caused primarily by
faulty pouring practices, but it also can be influenced by misplaced runners and risers.
Metalcasters can stop the defect from occurring by improving pouring conditions and
protecting the mold openings against metal splashing.
16.Irregular projections crop up on one side of a vertical casting surface near the
parting line.
Defect: Ramoff/RamawayThis defect is characterized by a thickening of the casting
in the vicinity of the parting line or an increase in dimension of a surface parallel to
the parting line. It is caused by improper mold creation (ramming), which has in turn
caused the sand to separate from certain vertical walls of the pattern.
17.Plate-like metallic projections with rough surfaces jut up parallel to the casting
f
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surface.
Defect: Kish Graphite InclusionsThis ferrous casting defect appears as coarse (not
smooth) porosity, filled with graphite. It generally becomes visible upon casting
machining. The defect is caused by an excessive carbon equivalent in the melt, slow
cooling or great differences in section thickness. A redesign on the part of the casting
end-user may be in order to address this defect.
18.Your iron casting shows local accumulations of coarse graphite. The graphite has
moved into the shrinkage cavities.
Defect:
Seams or Scars
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