Cast defect analysis is generally carried out after

the number of defects that occur in such a way that it

exceeds the allowable threshold.
To find this error, so that repairs can be carried out
properly, an effective analysis method is needed. The
following defect analysis procedures as suggested by
The American Foundry's Society are as follows:
1. Identification of Defects
2. Data Collection
 Gas hole are small and large holes caused by
trapped gas (gas that cannot come out of the mold cavity
during pouring or gases that appear in the liquid due to
certain reactions). The characteristics of the gas cavity
include:
a. Round shape,
b. Smooth surface,
c. Generally located on the upper surface,
d. Usually it appears following a slag defect.
 Causes of
No Information
Defects
a. The upper flask is not high enough, reducing metalostatic
1 Flask
pressure.
Casting a. The gating system results in turbulence,
2
Planning b. Long pour time.
 Causes of
No Information
Defects
a. Water level is too high,
Mold sand / b. Gas flow less,
3
core c. Foreign objects in sand that can cause gas (often occurs
in iron casting and non-ferrous casting).
a. The core is not dried,
b. The core is stored too long (CO2),
4 Core Making
c. Gas drainage is not good,
d. The core of furan is recycled too often (increasing N2).
 Causes of
No Information
Defects
a. Mold too hard,
b. Gas drainage is not good,
5 Mold Making c. Hot core is installed in the mold (condensation /
condensation occurs),
d. The core buffer and chill are rusty.
Metal
6 a. Effect of gas-causing materials (Bi, Pb, Sn, SB, etc.).
Composition
 Causes of
No Information
Defects
a. Oxidized liquid,
Melting b. Dirty raw materials,
7
process c. The smelting process is less than perfect,
d. Less degassing, especially for steel and non-ferro.
a. Cold pouring,
b. Integration in the ladel is less than perfect,
c. Dirty ladle,
8 Pouring
d. The position of the ladel is too high from the cast cup
(oxidation),
e. Slag remofer goes into the mold.
1. Problem Identification
a) Observation
A gas hole defect occurs during the shootblasting
process.
b) Data Collection
Data collection is carried out from the initial process to
the final process.
c) Analysis of causes
Analysis used with fish bone diagram.
 This gas hole defect occurs because the core (core)
is wet after coating and lack of gas gating in the pattern.
Improvement by heating the burner on the core
(core) that has been coated so as not to wet and repair
the pattern by adding gas lines. So that when the liquid
enters the gas it is not trapped in the mold cavity.
 (A) (B)
(A) Pressure Plat Pattern Sleeve PMI 165 Before Improve
(B) Swing Plat Pattern Sleeve PMI 165 Before Improve.
Standard Tapping and Pouring Temperature.
Temperatur Pouring Temperatur Tapping
Target Aktual Target Aktual
1370 - 1400 1390 1391 - 1410 1411

Standard Pouring Time.

Time Pouring
Mold 1 2 3 4 5 6 7 8 9 10
Time (detik) 15 16 15 14 19 18 19 19 18 19
Target 9 - 14 detik
Composition Data
COMPOSITION (%)

Komposisi
Base Metal Target Ladle
Kimia

Standar Aktual Standar Aktual

C 3.50 - 3.60% 3,55% 3.45 - 3.55 % 3,48%

Si 1.90 - 2.00 % 1,95% 2.20 - 2.30% 2,29%

Mn 0.60 - 0.70 % 0,64% 0.60 - 0.70 % 0,62%

S Max 0.20 % 0,009% Max 0.20 % 0.007%

P Max 0.10 % 0,025% Max 0.10 % 0.023%

Cr rest rest rest rest

Cu 0.15 - 0.20 % 0,019% 0.15 - 0.20 % 0,16%

Sn - - - -

Ni - - - -

Mg - - - -
 The results of the identification of the above
problems can be concluded that:
1) Viewed from the pouring temperature is in
accordance with the standard so that it can be
concluded that temperature is not the main cause of
defects in this product.
2) Longer than standard pouring / mold time can be a
factor in the occurrence of gas cavity defects in this
product.
3) The cores are moist because the core material is made
of alphaset.
4. The part on the casting which is filled with the last
lack of gas drain holes when filling metal liquid. This
can be a major cause of gas cavities in all PMI 165
products.
 Do additional ingate systems and also the addition
of gas lines

(A) (B)

(A) (B)
 The process of the burner core because previously
the cores that have been moistened are likely to have
defects in gas holes emerging from the moist core.

The purpose is to do the burner process on the core that

has been coated so as to reduce the moisture content in the
moist core.
 Kode Ins Reject % CRS MS GH BM
1T25A9 126 5 3,9 - 3 - 2

Time Pouring
Mold 1 2 3 4 5 6 7 8 9 10
Time (detik) 14 13 13 14 14 14 15 15 16 16
Target 9 - 14 detik

Casting the trial results of Slevee D4 PMI 165 after

repairing the pattern and burner core
 Casting the trial results of Slevee D4 PMI 165 after
repairing the pattern and burner core.
 Defects of gas holes that occur in the industry
affect the production process and delivery process to the
customer.
To reduce the defect of castings that occur in the
Sleeve D4 PMI 165 product and the ideal output
calculation of making D4 core sleeves it is recommended
that replacement of the manufacture material that
previously used the recommended alphaset material be
replaced into RCS material to accelerate the core output
and smooth the casting surface.