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what did you learn from the lecture today?

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what did you learn from the lecture today?

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Sektor perindustrian yang pesat dapat meningkatkan taraf hidup rakyat dan mengurangkan kadar pengangguran.

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One of the benefits is manufacturing industry is the ability to proactively complete maintenance.

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Encourage improvement of social services

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Manufacturing industries have helped in eradication of unemployment and poverty

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What do you think?

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Vision The best partner to investors distinguished by the integrity and professionalism of its people

Incorporated as a statutory body under the Malaysian Industrial Development Authority (MIDA) Act, the establishment of MIDA in 1967 was hailed by the World Bank as "the necessary impetus for purposeful, positive and coordinated promotional action" for Malaysia's industrial development. Today, MIDA is Malaysia's cutting-edge, dynamic and pioneering force in opening pathways to new frontiers around the globe.

MIDA assists companies which intend to invest in the manufacturing and services sectors, as well as facilitates the implementation of their projects. The wide range of services provided by MIDA include providing information on the opportunities for investments, as well as facilitating companies which are looking for joint venture partners.

Mission To ensure Malaysia achieves its goal in economic transformation and its aspiration of a developed nation by 2020

To further enhance MIDA's role in assisting investors, senior representatives from key government agencies are stationed at MIDA's headquarters in Kuala Lumpur to advise investors on government policies and procedures. These representatives include officials from the Department of Labour, Immigration Department, Royal Malaysian Customs, Department of Environment, Tenaga Nasional Berhad and Telekom Malaysia Berhad.

MIDA also evaluates the following applications for projects in the manufacturing and its related services sectors:

Manufacturing licenses

Tax incentives

Expatriate posts

Duty exemptions on raw materials and components

Duty exemptions on machinery and equipment for agricultural sector and selected services sector

With the implementation of the self-declaration mechanism for granting import duty exemption on machinery, equipment, spare parts, consumables, prime movers and container trailers for manufacturers in the principal customs area (PCA), companies engaged in a hotel business and haulage operators effective 2nd May 2014, MIDA is also responsible to issue a Confirmation Letter on the status of the applicant prior to seeking the permission from the Royal Malaysian Customs Department to claim for the exemption.

Investors are encouraged to discuss their project interests with MIDA officers at MIDA's headquarters in Kuala Lumpur or at its overseas or state offices closest to them. Information on investing can also be obtained from the Getting Started section. Investors are also invited to visit MIDA's Business Information Centre (BIC) where published information on investment, trade, financing, productivity pertaining to the manufacturing and services sectors are available.

The Business Information Center is located at :

Malaysian Investment Development Authority

Level 2, MIDA Sentral
No.5, Jalan Stesen Sentral 5
Kuala Lumpur Sentral
50470 Kuala Lumpur
Malaysia

Tel: 603 2267 3633 / 2263 2555 / 2263 2549
Fax: 603 2274 7970
Email :[email protected]
Website :www.mida.gov.my Operating Hours : Mon - Fri 8.30 a.m. - 5.00 p.m.

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Vision The best partner to investors distinguished by the integrity and professionalism of its people Incorporated as a statutory body under the Malaysian Industrial Development Authority (MIDA) Act, the establishment of MIDA in 1967 was hailed by the World Bank as "the necessary impetus for purposeful, positive and coordinated promotional action" for Malaysia's industrial development.

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Hi kitorang group customer (outdoor furniture)

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Hi kitorang group customer (outdoor furniture)

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Group manufacturer
(Outdoor furniture)

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Group customer ( Kitchen Cabinet )

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Group Customer ( Cooking Pan)

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Manufacturers (cooking pan)

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i learn how to make product based on materials

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Today im learn about how to choose a metarials to produce a better things and I learn how to do a research first at any cost to unsure that the thing functional well

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Materials include metals, ceramic and polymers. Know the function of materials before choose the material

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Every product have their function

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I get some knowledge about how to use the materials correctly.

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Can now what materials that suitable to use in manufacturing

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What products made from casting? tell your partner!

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What products made from casting? tell your partner!

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the winner of the day is.....

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what are the additional steps in investment casting that do not have in sand casting?

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what are the additional steps in investment casting that do not have in sand casting?

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hoorayy..WINNER of the day @Geetha

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Play a game of Kahoot! here. Kahoot! is a free game-based learning platform that makes it fun to learn - any subject, in any language, on any device, for all ages!

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In a group, discuss the type of defects given based on:
1. what causes the defects
2. how to overcome the defects
3. present your work to other groups
4. upload your presentation here (video/ notes)
5. each group have to assess their fellow groups presentation
6. Short quiz will be conducted in the next class on this topic

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Are your products suffering from casting defects? The good news is they're entirely preventable. Read on for causes and prevention of the top casting defects.

Your cast iron metal pan leaves the factory with pinholes, leading to a slew of complaints from your customers. What happened? How could you have prevented this from happening?

Foundry production is a complex multi-step process. The technical level of each process varies greatly. Skills of the operator, quality management and equipment can all affect the final quality of the casting.

The key to preventing product defects in your casted products is to set clear expectations and tolerances for quality issues with your supplier ( related: How Experienced Importers Limit Product Defects in 3 Stages [eBook]).

But before you can do that, you need to have a clear understanding of the different types of casting defects and their causes. Only then can you prevent casting defects and avoid sending defective products to your customers.

Read on or click the links below to jump to the section for each of these types of casting defects.

Gas porosity casting defects and causes

Gas porosity occurs when the metal traps gas (most often nitrogen, oxygen or hydrogen) during casting.

When the casting cools and solidifies, bubbles form because the solid form of the metal cannot hold as much gas as the liquid form. These bubbles appear on a casting as rounded, circular cavities or holes.

There are three types of casting defects related to gas porosity:

1. Pinholes

Pinholes, also sometimes referred to as porosities, are very tiny holes (about 2 mm) usually found in the cope (upper) part of the mold, in poorly vented pockets.

They usually appear in large numbers together, either at the surface or just below the surface of the casting. They are always visible to the naked eye and don't require equipment to identify.

2. Subsurface blowhole

Blowholes, or simply blows, are larger cavities than pinholes.

A subsurface blowhole appears on the inside of a cast and usually isn't visible until after machining.

Subsurface blowholes can be difficult to detect before machining, requiring harmonic, ultrasonic, magnetic or x-ray analysis.

3. Open holes

These blowholes appear on the surface of the cast and are easier to detect than subsurface blowholes.

Causes and prevention of gas porosity

There are several causes of cavity defects.

Poor venting of mold and cores

Insufficient drying of mold and cores

How can you prevent gas porosity?

Scars are shallow blows that appear on a flat surface, while blisters are scars covered with a thin layer of metal.

Excessive moisture content of molding sand

Inadequate gas permeability of molding sand

Potential solutions include:

Incorporate good fluxing and melting practices: melt metal in a vacuum, in an environment of low-solubility gases or under a flux that prevents contact with the air

Increase gas permeability of sand: coarser sands have a higher permeability

Increase permeability of mold and cores. Allow air and gas to escape from the mold cavity

Dry out molds and cores before use and store dry

Increase rate of solidification by reducing metal temperature during casting

Shrinkage casting defects and causes

Shrinkage occurs because metals are less dense as a liquid than a solid.

A shrinkage cavity is a depression in a casting which occurs during the solidification process. Shrinkage porosity appears with angular edges, compared to the round surfaces of gas porosity. Cavities might also be paired with dendritic fractures or cracks.

Large shrinkage cavities can undermine the integrity of the casting and may cause it to eventually break under stress.

Shrinkage can result in two types of casting defects.

4. Open shrinkage defects

These are open to the atmosphere. Air compensated as the shrinkage cavity forms.

Pipes are open shrinkage defects that form at the surface and burrow into the casting. Caved surfaces are shallow, open shrinkage defects that form across the surface of the casting.

5. Closed shrinkage defects

Also known as shrinkage porosity, closed shrinkage defects form within the casting. Macro shrinkage can be viewed with the naked eye, but micro shrinkage cannot.

Closed shrinkage defects usually appear at the top of hot spots, or isolated pools of hot liquid.

Prevent shrinkage cavities by improving casting structure

Alloys always shrink when changing from molten to solid. This is because the density of a casting alloy in the molten state is lower than that in the solid state.

You should expect some shrinkage during solidification. Factor a shrinkage allowance into the pattern design before casting.

You can prevent shrinkage casting defects by improving the overall casting structure:

Design a running (gate) system with risers that ensure a continuous flow of molten metal

Increase local heat dissipation by inserting internal chills, cooling ribs or cooling coils

Reduce casting temperature to limit the total volume deficit

Mold material casting defects and causes

Mold material casting defects are related to the mold material, which is most commonly sand. You and your supplier can typically address these casting defects and causes by modifying the mold.

6. Cuts and washes

Cuts and washes are areas of excess metal. These appear when the molten metal erodes the molding sand.

A cut appears as a low projection along the surface of the drag face, decreasing in height as it extends from one side of the casting to the other.

Causes and prevention of cuts and washes

Cuts and washes can be caused by molten metal flowing at a high velocity, causing too much metal to flow through the gate.

You can prevent cuts and washes easiest by:

Designing the gating system properly

Improving mold and core strength

Adding more binders to the facing and core sand

7. Fusion

Fusion occurs when sand grains fuse with molten metal. It appears as a thin crust with a brittle, glassy appearance firmly adhered to the casting.

Causes and prevention of fusion

Two main factors can cause fusion:

Improving the refractoriness of the molding material and/or reducing the pouring temperature of the molten metal will help prevent fusion.

8. Run out

Run out is when liquid metal leaks out of the mold, leading to an incomplete or missing casting.

A faulty mold or flask is responsible for run out.

Prevention of run out and incomplete castings

To prevent this casting defect, design the casting mold with precision. Inspect and replace any defective molds before casting.

High temperatures can lead to excess wear and tear of the mold. Use quality raw materials for your mold that can resist high temperatures.

9. Swells

Swells are an enlargement of the casting. Swells typically take on the shape of a slight, smooth bulge on the vertical face of castings.

Causes and prevention of swells

Swell is usually caused by improper or soft ramming of the mold or a low strength mold.

Molds should be built to withstand liquid metal pressure. Otherwise, the mold wall may give way or move back, causing swelling.

Using a strong, properly rammed mold prevents swells.

10. Drops

Drops occur when pieces of sand fall into metal casting when it's still liquid. Drops appear as an irregularly shaped projection on the cope (top) surface of a casting.

Causes and prevention of drops

Four potential causes for drops and their preventions include:

11. Rat tails, veins and buckles

Rat tails, or v eins, appear as an irregular line or crack on the casting, when the surface of the molding sand buckles up. Rat tails usually occur on the surface of the mold bottom, an area covered with molten material.

Buckles are a more severe form of rat tails.

Causes and prevention of rat tails and buckles

Rat tails and buckles occur when excessive heat of the metal causes the sand to expand. This may be caused by:

Poor mold design : Large and flat sections are more prone to rat tails. The mold also should not be too hard, as it must allow for proper expansion.

12. Metal penetration

Metal penetration occurs when liquid metal penetrates gaps in the molding sand. The penetration is visible to the naked eye as a rough and uneven surface finish of the casting.

Causes and prevention of metal penetration

Metal penetration is due to:

Use of sand with low strength and high permeability

Use of large or coarse sand grain: the coarser the sand grains, the more severe the metal penetration

Lack of mold wash

Soft ramming of sand

Prevent metal penetration by fixing these areas. Use high strength, small grain size, low permeability and hard ramming of sand. Ensure a protective barrier against metal penetration by coating the surface of molds with a mold wash.

You can typically remove metal penetration by grinding down the rough surface of the casting.

Metallurgical casting defects and causes

There are two types of metallurgical defects to watch out for.

13. Hot tear/crack

Cracks appear in the form of irregular crevices in a branched pattern.

Some cracks are obvious and easily seen, while others can require magnification.

Cracks occur as the casting cools, towards the end of solidification.

Causes and prevention of hot tears and cracks

If the solidifying metal does not have sufficient strength to resist tensile forces during solidification, hot tears will appear.

Hot tears are mostly caused by poor mold design. Modifying the mold to improve collapsibility can easily resolve these issues.

14. Hot/hard spots

Hot spots are spots that are harder than the surrounding area. This is because they cooled more quickly than the surrounding material.

Hard spots can interfere with machining and increase tool wear.

Causes and prevention of hot spots

Hot spots are a direct result of improper cooling practices. There are two potential solutions if hot spots are your problem:

Start by correcting cooling practice

Also consider changing the metal's chemical composition

Pouring casting defects and causes

Pouring metal defects arise during the process of pouring metal into the mold. If you have a pouring metal defect, it will fall into one of these categories:

15. Cold shut/lap

Cold shut is a type of surface defect. You'll see a line or crack with a round edge on the casting surface.

This defect is visible to the naked eye and often results in rejecting the cast, as it creates a weak spot.

Causes and prevention of cold shut

When molten metal enters the mold from two gates, the streams will meet at a junction. Low temperatures can prevent fusion at the junction, causing the streams to solidify before fusion, creating a cold shut.

Cold shut is usually a result of a lack of fluidity of the molten metal, or a poor design of the gating system.

The best way to prevent cold shuts is to increase fluidity of the molten metal. This can be done in a few ways:

Optimize gating system to minimize narrow cross-paths and ensure short flow paths

Increase the pouring temperature to prevent premature solidification

Improve gas permeability of the mold (through coarser grain size, etc.)

16. Misruns are closely related to cold shuts

Misruns occur when the liquid metal is too cold to flow to the extremities of the mold cavity before freezing and solidifying.

The liquid metal does not completely fill the mold cavity. The misrun is the unfilled portion or space in the mold.

Causes and prevention of misruns

The reasons for premature solidification are similar to those for cold shut. If you have a misrun, check:

Mold design

Gating system design and

Molten metal fluidity

17. Cold shots

Splattering during pouring of a liquid can cause solid globules to form.

As these globules freeze, they become entrapped in the casting.

Cold shots are typically ball, drop or pearl shaped and loosely attached to the metal.

Causes and prevention of cold shots

To prevent splattering and cold shots, consider

Modifying pouring procedures to minimize turbulence

Adjusting gating system designs to reduce gate speed

18. Slag inclusion (scab)

These irregular metallic crusts are found on the casting surface. Scabs are typically only a few millimeters thick but can be seen by the naked eye. They usually have sharp edges, irregular shapes and are firmly bonded to the casting.

Scabs are closely related to rat tails and they usually appear together. Removal of scabs will typically reveal a rat tail underneath.

Causes and prevention of slag inclusion

Slag inclusion is caused when molten metal containing slag particles is poured into the mold cavities and solidifies.

Preventing slag inclusion is a simple fix. Remove slag particles from the molten metal before pouring it into the mold cavity.

You can remove slag by:

Melting the metal with a flux, in a vacuum or in an inert atmosphere

Adding ingredients to the mixture to cause slag to float to the top where you can easily see and remove it before pouring. Or use a special ladle that pours metal from the bottom.

Adding a ceramic filter into the gating system

Casting shape defects and causes

These types of casting defects are related to the overall shape of the final casting.

19. Shift/mismatch

Mold shift is due to misalignment of upper (cope) and lower (drag) part of the mold. Mold shift is usually reflected as a horizontal displacement.

Core shift is similar to mold shift, but it's the core that is misaligned, not the mold. Core shift is usually reflected as a vertical displacement.

Causes and prevention of shift

Some causes of shift can include:

Loose box pins

Inaccurate pattern dowel pins or

Carelessness in placing the cope on the drag, causing misalignment

If you're experiencing shift, try checking the match plate pattern mounting and alignment. Make sure to use proper molding box and closing pins.

20. Flash, fin and burrs

Flash is one of the most frequently occurring casting defects and also a common injection molding defect.

Flash, also known as casting fin or burrs, is any unwanted and excess material attached to a cast. It's typically a thin sheet of metal that forms at the parting faces. Flash is a waste material that turns into dross after being re-melted.

Causes and prevention of flash, fin and burrs

Flash on the casting surface is due to a crack or gap on the core surface. Insufficient weight on the mold or improper clamping of the flask can lead to a gap.

Remedy this issue by reassembling the mold and cores. There should be enough weight on the top part of the mold so that the two parts fit together tightly.

Flash can vary from minor to very serious. If it's not too serious, manufacturers can remove flash by breaking it off with a hammer or pliers and filing it down to the parting line. However, this can be a costly process.

21. Warping

Warping is an unwanted casting deformity that can occur over time, which results in a change in the dimensions of the final product.It can happen during or after solidification.

Causes and prevention of warping

Warping is typically a result of different rates of solidifications of different sections, which causes stress in adjoining walls. Large and flat sections are more prone to warping.

Normalizing heat treatment can remove residual stress in iron casting. A straightening between quench and aging processes might also be required for aluminum casting.

Conclusion

Knowledge of casting defects and causes is essential to managing casting quality.

You should set clear defect tolerances and quality expectations with your suppliers before production to help them understand your quality standards.

Defect tolerance can vary between products and types of casting defects. Determining your tolerance for these casting defects can help your supplier better understand your standards and prevent future misunderstandings and quality issues.

Ultimately, the manufacturer must strictly control quality of each casting process. Experienced importers rely on quality control inspections to limit casting defects in their products before they leave the factory.
Do you have experience in addressing any of these casting defects? Share your tips in the comment section below!

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21 Casting Defects and How to Prevent Them in Your Products

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Are your products suffering from casting defects? The good news is they're entirely preventable. Read on for causes and prevention of the top casting defects. Your cast iron metal pan leaves the factory with pinholes, leading to a slew of complaints from your customers. What happened? How could you have prevented this from happening?

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It is an unwanted irregularities that appear in the casting during metal casting process. There is various reason or sources which is responsible for the defects in the cast metal. Here in this section we will discuss all the major types of casting defects. Some of the defects produced may be neglected or tolerated and some are not acceptable, it must be eliminated for better functioning of the parts.

Types

Casting defects can be categorized into 5 types

1. Gas Porosity: Blowholes, open holes, pinholes
2. Shrinkage defects: shrinkage cavity
3. Mold material defects: Cut and washes, swell, drops, metal penetration, rat tail
4. Pouring metal defects: Cold shut, misrun, slag inclusion
5. Metallurgical defects: Hot tears, hot spot.

The various casting defects that appear in the casting process are

The defect caused due to misalignment of upper and lower part of the casting and misplacement of the core at parting line.
Cause:
(i) Improper alignment of upper and lower part during mold preparation.
(ii) Misalignment of flask (a flask is type of tool which is used to contain a mold in metal casting. it may be square, round, rectangular or of any convenient shape.)
Remedies
(i) Proper alignment of the pattern or die part, molding boxes.
(ii) Correct mountings of pattern on pattern plates.
(iii) Check the alignment of flask.

It is the enlargement of the mold cavity because of the molten metal pressure, which results in localised or overall enlargement of the casting.
Causes
(i) Defective or improper ramming of the mold.
Remedies
(i) The sand should be rammed properly and evenly.

When gases entrapped on the surface of the casting due to solidifying metal, a rounded or oval cavity is formed called as blowholes. These defects are always present in the cope part of the mold.
Causes
(i) Excessive moisture in the sand.
(ii) Low Permeability of the sand.
(iii) Sand grains are too fine.
(iv) Too hard rammed sand.
(v) Insufficient venting is provided.
Remedies
(i) The moisture content in the sand must be controlled and kept at desired level.
(ii) High permeability sand should be used.
(iii) Sand of appropriate grain size should be used.
(iv) Sufficient ramming should be done.
(v) Adequate venting facility should be provided.

Drop defect occurs when there is cracking on the upper surface of the sand and sand pieces fall into the molten metal.
Causes
(i) Soft ramming and low strength of sand.
(ii) Insufficient fluxing of molten metal. Fluxing means addition of a substance in molten metal to remove impurities. After fluxing the impurities from the molten metal can be easily removed.
(iii) Insufficient reinforcement of sand projections in the cope.
Remedies
(i) Sand of high strength should be used with proper ramming (neither too hard nor soft).
(ii) There should be proper fluxing of molten metal, so the impurities present in molten metal is removed easily before pouring it into the mold.
(iii) Sufficient reinforcement of the sand projections in the cope.

These casting defects appear as an uneven and rough surface of the casting. When the size of sand grains is larges, the molten fuses into the sand and solidifies giving us metal penetration defect.
Causes
(i) It is caused due to low strength, large grain size, high permeability and soft ramming of sand. Because of this the molten metal penetrates in the molding sand and we get rough or uneven casting surface.
Remedies
(ii) This defect can be eliminated by using high strength, small grain size, low permeability and soft ramming of sand.

They are very small holes of about 2 mm in size which appears on the surface of the casting. This defect happens because of the dissolution of the hydrogen gases in the molten metal. When the molten metal is poured in the mold cavity and as it starts to solidify, the solubility of the hydrogen gas decreases and it starts escaping out the molten metal leaves behind small number of holes called as pinholes.
Causes
(i) Use of high moisture content sand.
(ii) Absorption of hydrogen or carbon monoxide gas by molten metal.
(iii) Pouring of steel from wet ladles or not sufficiently gasified.
Remedies
(i) By reducing the moisture content of the molding sand.
(ii) Good fluxing and melting practices should be used.
(iii) Increasing permeability of the sand.
(iv) By doing rapid rate of solidification.

The formation of cavity in the casting due to volumetric contraction is called as shrinkage cavity.
Causes
(i) Uneven or uncontrolled solidification of molten metal.
(ii) Pouring temperature is too high.
Remedies
(i) This defect can be removed by applying principle of directional solidification in mold design.
(ii) Wise use of chills (a chill is an object which is used to promote solidification in a specific portion of a metal casting) and padding.

It is a type of surface defects and a line on the surface can be seen. When the molten metal enters into the mold from two gates and when these two streams of molten metal meet at a junction with low temperatures than they do not fuse with each other and solidifies creating a cold shut (appear as line on the casting). It looks like a crack with round edge.
Causes
(i) Poor gating system
(ii) Low melting temperature
(iii) Lack of fluidity
Remedies
(i) Improved gating system.
(ii) Proper pouring temperature.

When the molten metal solidifies before completely filling the mold cavity and leaves a space in the mold called as misrun.
Causes
(i) Low fluidity of the molten metal.
(ii) Low temperature of the molten metal which decreases its fluidity.
(iii) Too thin section and improper gating system.
Remedies
(i) Increasing the pouring temperature of the molten metal increases the fluidity.
(ii) Proper gating system
(iii) Too thin section is avoided.

This defect is caused when the molten metal containing slag particles is poured in the mold cavity and it gets solidifies.
Causes
(i) The presence of slag in the molten metal
Remedies
(i) Remove slag particles form the molten metal before pouring it into the mold cavity.

when the metal is hot it is weak and the residual stress (tensile) in the material cause the casting fails as the molten metal cools down. The failure of casting in this case is looks like cracks and called as hot tears or hot cracking.
Causes
(i) Improper mold design.
Remedies
(i) Proper mold design can easily eliminate these types of casting defects.
(ii) Elimination of residual stress from the material of the casting.

Hot spot defects occur when an area on the casting cools more rapidly than the surrounding materials. Hot spot are areas on the casting which is harder than the surrounding area. It is also called as hard spot.
Causes
(i) The rapid cooling an area of the casting than the surrounding materials causes this defect.
Remedies
(i) This defect can be avoided by using proper cooling practice.
(ii) By changing the chemical composition of the metal.

It is the holes created on the external surface or inside the casting. It occurs when loose sand washes into the mold cavity and fuses into the interior of the casting or rapid pouring of the molten metal.
Causes:
(i) Loose ramming of the sand.
(ii) Rapid pouring of the molten metal into the mold results in wash away of sand from the mold and a hole is created.
(iii) Improper cleaning of the mold cavity.
Remedies
(i) Proper ramming of the sand.
(ii) Molten metal should be poured carefully in the mold.
(iii) Proper cleaning of the molten cavity eliminates sand holes.

The embedding of particles of dust and sand in the casting surface, results in dirt defect.
Causes:
(i) Cursing of mold due to improper handling and Sand wash (A sloping surface of sand that spread out by stream of molten metal).
(ii) Presence of slag particles in the molten metal.
Remedies:
(i) Proper handling of the mold to avoid crushing.
(ii) Sufficient fluxing should be done to remove slag impurities from molten metal.

It is an external defect in which there is a number of small cavities in close proximity present in the metal casting.
Causes:
(i) It is caused due to dirt and scurf held mechanically in the suspension of the molten metal.
(ii) Due to imperfect skimming in the ladle.
Remedies
(i) Prevent the entry of dirt and scurf in the molten metal.
(ii) Prevent sand wash.
(iii) Remove slag materials from the molten metal by proper skimming in the ladle.

It is an accidental and unwanted deformation in the casting that happens during or after solidification. Due to this defect, the dimension of the final product changes.
Causes:
(i) Due to different rates of solidification of different sections. This induces stresses in adjoining walls and result in warpage.
(ii) Large and flat sections or intersecting section such as ribs are more prone to these casting defects.
Remedies
(i) It can be prevented by producing large areas with wavy, corrugated construction, or add sufficient rib-like shape, to provide equal cooling rates in all areas.
(ii) Proper casting designs can reduce these defects more efficiently.

A thin projection of metal, not considered as a part of casting is called as fins or fin. It is usually occurs at the parting of the mold or core section.

Causes:

(i) Incorrect assembling of mold and cores.
(ii) Insufficient weight of the mold or improper clamping of the flask may produce the fins.
Remedies
(i) Correct assembly of the mold and cores.
(ii) There should be sufficient weight on the top part of the mold so that the two parts fit together tightly.

Here we have discussed about what is casting defects - types, causes and remedies to eliminate it. If you like this post than dont forget to share it on google+ and Facebook. If you find any query regarding this post feel free to ask.

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What is Casting Defects - Types, Causes and Remedies? - Mechanical Booster

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It is an unwanted irregularities that appear in the casting during metal casting process. There is various reason or sources which is responsible for the defects in the cast metal. Here in this section we will discuss all the major types of casting defects.

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Are your products suffering from casting defects? The good news is they're entirely preventable. Read on for causes and prevention of the top casting defects.

Your cast iron metal pan leaves the factory with pinholes, leading to a slew of complaints from your customers. What happened? How could you have prevented this from happening?

Foundry production is a complex multi-step process. The technical level of each process varies greatly. Skills of the operator, quality management and equipment can all affect the final quality of the casting.

The key to preventing product defects in your casted products is to set clear expectations and tolerances for quality issues with your supplier ( related: How Experienced Importers Limit Product Defects in 3 Stages [eBook]).

But before you can do that, you need to have a clear understanding of the different types of casting defects and their causes. Only then can you prevent casting defects and avoid sending defective products to your customers.

Read on or click the links below to jump to the section for each of these types of casting defects.

Gas porosity casting defects and causes

Gas porosity occurs when the metal traps gas (most often nitrogen, oxygen or hydrogen) during casting.

When the casting cools and solidifies, bubbles form because the solid form of the metal cannot hold as much gas as the liquid form. These bubbles appear on a casting as rounded, circular cavities or holes.

There are three types of casting defects related to gas porosity:

1. Pinholes

Pinholes, also sometimes referred to as porosities, are very tiny holes (about 2 mm) usually found in the cope (upper) part of the mold, in poorly vented pockets.

They usually appear in large numbers together, either at the surface or just below the surface of the casting. They are always visible to the naked eye and don't require equipment to identify.

2. Subsurface blowhole

Blowholes, or simply blows, are larger cavities than pinholes.

A subsurface blowhole appears on the inside of a cast and usually isn't visible until after machining.

Subsurface blowholes can be difficult to detect before machining, requiring harmonic, ultrasonic, magnetic or x-ray analysis.

3. Open holes

These blowholes appear on the surface of the cast and are easier to detect than subsurface blowholes.

Causes and prevention of gas porosity

There are several causes of cavity defects.

Poor venting of mold and cores

Insufficient drying of mold and cores

How can you prevent gas porosity?

Scars are shallow blows that appear on a flat surface, while blisters are scars covered with a thin layer of metal.

Excessive moisture content of molding sand

Inadequate gas permeability of molding sand

Potential solutions include:

Incorporate good fluxing and melting practices: melt metal in a vacuum, in an environment of low-solubility gases or under a flux that prevents contact with the air

Increase gas permeability of sand: coarser sands have a higher permeability

Increase permeability of mold and cores. Allow air and gas to escape from the mold cavity

Dry out molds and cores before use and store dry

Increase rate of solidification by reducing metal temperature during casting

Shrinkage casting defects and causes

Shrinkage occurs because metals are less dense as a liquid than a solid.

A shrinkage cavity is a depression in a casting which occurs during the solidification process. Shrinkage porosity appears with angular edges, compared to the round surfaces of gas porosity. Cavities might also be paired with dendritic fractures or cracks.

Large shrinkage cavities can undermine the integrity of the casting and may cause it to eventually break under stress.

Shrinkage can result in two types of casting defects.

4. Open shrinkage defects

These are open to the atmosphere. Air compensated as the shrinkage cavity forms.

Pipes are open shrinkage defects that form at the surface and burrow into the casting. Caved surfaces are shallow, open shrinkage defects that form across the surface of the casting.

5. Closed shrinkage defects

Also known as shrinkage porosity, closed shrinkage defects form within the casting. Macro shrinkage can be viewed with the naked eye, but micro shrinkage cannot.

Closed shrinkage defects usually appear at the top of hot spots, or isolated pools of hot liquid.

Prevent shrinkage cavities by improving casting structure

Alloys always shrink when changing from molten to solid. This is because the density of a casting alloy in the molten state is lower than that in the solid state.

You should expect some shrinkage during solidification. Factor a shrinkage allowance into the pattern design before casting.

You can prevent shrinkage casting defects by improving the overall casting structure:

Design a running (gate) system with risers that ensure a continuous flow of molten metal

Increase local heat dissipation by inserting internal chills, cooling ribs or cooling coils

Reduce casting temperature to limit the total volume deficit

Mold material casting defects and causes

Mold material casting defects are related to the mold material, which is most commonly sand. You and your supplier can typically address these casting defects and causes by modifying the mold.

6. Cuts and washes

Cuts and washes are areas of excess metal. These appear when the molten metal erodes the molding sand.

A cut appears as a low projection along the surface of the drag face, decreasing in height as it extends from one side of the casting to the other.

Causes and prevention of cuts and washes

Cuts and washes can be caused by molten metal flowing at a high velocity, causing too much metal to flow through the gate.

You can prevent cuts and washes easiest by:

Designing the gating system properly

Improving mold and core strength

Adding more binders to the facing and core sand

7. Fusion

Fusion occurs when sand grains fuse with molten metal. It appears as a thin crust with a brittle, glassy appearance firmly adhered to the casting.

Causes and prevention of fusion

Two main factors can cause fusion:

Improving the refractoriness of the molding material and/or reducing the pouring temperature of the molten metal will help prevent fusion.

8. Run out

Run out is when liquid metal leaks out of the mold, leading to an incomplete or missing casting.

A faulty mold or flask is responsible for run out.

Prevention of run out and incomplete castings

To prevent this casting defect, design the casting mold with precision. Inspect and replace any defective molds before casting.

High temperatures can lead to excess wear and tear of the mold. Use quality raw materials for your mold that can resist high temperatures.

9. Swells

Swells are an enlargement of the casting. Swells typically take on the shape of a slight, smooth bulge on the vertical face of castings.

Causes and prevention of swells

Swell is usually caused by improper or soft ramming of the mold or a low strength mold.

Molds should be built to withstand liquid metal pressure. Otherwise, the mold wall may give way or move back, causing swelling.

Using a strong, properly rammed mold prevents swells.

10. Drops

Drops occur when pieces of sand fall into metal casting when it's still liquid. Drops appear as an irregularly shaped projection on the cope (top) surface of a casting.

Causes and prevention of drops

Four potential causes for drops and their preventions include:

11. Rat tails, veins and buckles

Rat tails, or v eins, appear as an irregular line or crack on the casting, when the surface of the molding sand buckles up. Rat tails usually occur on the surface of the mold bottom, an area covered with molten material.

Buckles are a more severe form of rat tails.

Causes and prevention of rat tails and buckles

Rat tails and buckles occur when excessive heat of the metal causes the sand to expand. This may be caused by:

Poor mold design : Large and flat sections are more prone to rat tails. The mold also should not be too hard, as it must allow for proper expansion.

12. Metal penetration

Metal penetration occurs when liquid metal penetrates gaps in the molding sand. The penetration is visible to the naked eye as a rough and uneven surface finish of the casting.

Causes and prevention of metal penetration

Metal penetration is due to:

Use of sand with low strength and high permeability

Use of large or coarse sand grain: the coarser the sand grains, the more severe the metal penetration

Lack of mold wash

Soft ramming of sand

Prevent metal penetration by fixing these areas. Use high strength, small grain size, low permeability and hard ramming of sand. Ensure a protective barrier against metal penetration by coating the surface of molds with a mold wash.

You can typically remove metal penetration by grinding down the rough surface of the casting.

Metallurgical casting defects and causes

There are two types of metallurgical defects to watch out for.

13. Hot tear/crack

Cracks appear in the form of irregular crevices in a branched pattern.

Some cracks are obvious and easily seen, while others can require magnification.

Cracks occur as the casting cools, towards the end of solidification.

Causes and prevention of hot tears and cracks

If the solidifying metal does not have sufficient strength to resist tensile forces during solidification, hot tears will appear.

Hot tears are mostly caused by poor mold design. Modifying the mold to improve collapsibility can easily resolve these issues.

14. Hot/hard spots

Hot spots are spots that are harder than the surrounding area. This is because they cooled more quickly than the surrounding material.

Hard spots can interfere with machining and increase tool wear.

Causes and prevention of hot spots

Hot spots are a direct result of improper cooling practices. There are two potential solutions if hot spots are your problem:

Start by correcting cooling practice

Also consider changing the metal's chemical composition

Pouring casting defects and causes

Pouring metal defects arise during the process of pouring metal into the mold. If you have a pouring metal defect, it will fall into one of these categories:

15. Cold shut/lap

Cold shut is a type of surface defect. You'll see a line or crack with a round edge on the casting surface.

This defect is visible to the naked eye and often results in rejecting the cast, as it creates a weak spot.

Causes and prevention of cold shut

When molten metal enters the mold from two gates, the streams will meet at a junction. Low temperatures can prevent fusion at the junction, causing the streams to solidify before fusion, creating a cold shut.

Cold shut is usually a result of a lack of fluidity of the molten metal, or a poor design of the gating system.

The best way to prevent cold shuts is to increase fluidity of the molten metal. This can be done in a few ways:

Optimize gating system to minimize narrow cross-paths and ensure short flow paths

Increase the pouring temperature to prevent premature solidification

Improve gas permeability of the mold (through coarser grain size, etc.)

16. Misruns are closely related to cold shuts

Misruns occur when the liquid metal is too cold to flow to the extremities of the mold cavity before freezing and solidifying.

The liquid metal does not completely fill the mold cavity. The misrun is the unfilled portion or space in the mold.

Causes and prevention of misruns

The reasons for premature solidification are similar to those for cold shut. If you have a misrun, check:

Mold design

Gating system design and

Molten metal fluidity

17. Cold shots

Splattering during pouring of a liquid can cause solid globules to form.

As these globules freeze, they become entrapped in the casting.

Cold shots are typically ball, drop or pearl shaped and loosely attached to the metal.

Causes and prevention of cold shots

To prevent splattering and cold shots, consider

Modifying pouring procedures to minimize turbulence

Adjusting gating system designs to reduce gate speed

18. Slag inclusion (scab)

These irregular metallic crusts are found on the casting surface. Scabs are typically only a few millimeters thick but can be seen by the naked eye. They usually have sharp edges, irregular shapes and are firmly bonded to the casting.

Scabs are closely related to rat tails and they usually appear together. Removal of scabs will typically reveal a rat tail underneath.

Causes and prevention of slag inclusion

Slag inclusion is caused when molten metal containing slag particles is poured into the mold cavities and solidifies.

Preventing slag inclusion is a simple fix. Remove slag particles from the molten metal before pouring it into the mold cavity.

You can remove slag by:

Melting the metal with a flux, in a vacuum or in an inert atmosphere

Adding ingredients to the mixture to cause slag to float to the top where you can easily see and remove it before pouring. Or use a special ladle that pours metal from the bottom.

Adding a ceramic filter into the gating system

Casting shape defects and causes

These types of casting defects are related to the overall shape of the final casting.

19. Shift/mismatch

Mold shift is due to misalignment of upper (cope) and lower (drag) part of the mold. Mold shift is usually reflected as a horizontal displacement.

Core shift is similar to mold shift, but it's the core that is misaligned, not the mold. Core shift is usually reflected as a vertical displacement.

Causes and prevention of shift

Some causes of shift can include:

Loose box pins

Inaccurate pattern dowel pins or

Carelessness in placing the cope on the drag, causing misalignment

If you're experiencing shift, try checking the match plate pattern mounting and alignment. Make sure to use proper molding box and closing pins.

20. Flash, fin and burrs

Flash is one of the most frequently occurring casting defects and also a common injection molding defect.

Flash, also known as casting fin or burrs, is any unwanted and excess material attached to a cast. It's typically a thin sheet of metal that forms at the parting faces. Flash is a waste material that turns into dross after being re-melted.

Causes and prevention of flash, fin and burrs

Flash on the casting surface is due to a crack or gap on the core surface. Insufficient weight on the mold or improper clamping of the flask can lead to a gap.

Remedy this issue by reassembling the mold and cores. There should be enough weight on the top part of the mold so that the two parts fit together tightly.

Flash can vary from minor to very serious. If it's not too serious, manufacturers can remove flash by breaking it off with a hammer or pliers and filing it down to the parting line. However, this can be a costly process.

21. Warping

Warping is an unwanted casting deformity that can occur over time, which results in a change in the dimensions of the final product.It can happen during or after solidification.

Causes and prevention of warping

Warping is typically a result of different rates of solidifications of different sections, which causes stress in adjoining walls. Large and flat sections are more prone to warping.

Normalizing heat treatment can remove residual stress in iron casting. A straightening between quench and aging processes might also be required for aluminum casting.

Conclusion

Knowledge of casting defects and causes is essential to managing casting quality.

You should set clear defect tolerances and quality expectations with your suppliers before production to help them understand your quality standards.

Defect tolerance can vary between products and types of casting defects. Determining your tolerance for these casting defects can help your supplier better understand your standards and prevent future misunderstandings and quality issues.

Ultimately, the manufacturer must strictly control quality of each casting process. Experienced importers rely on quality control inspections to limit casting defects in their products before they leave the factory.
Do you have experience in addressing any of these casting defects? Share your tips in the comment section below!

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21 Casting Defects and How to Prevent Them in Your Products

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Are your products suffering from casting defects? The good news is they're entirely preventable. Read on for causes and prevention of the top casting defects. Your cast iron metal pan leaves the factory with pinholes, leading to a slew of complaints from your customers. What happened? How could you have prevented this from happening?

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It is an unwanted irregularities that appear in the casting during metal casting process. There is various reason or sources which is responsible for the defects in the cast metal. Here in this section we will discuss all the major types of casting defects. Some of the defects produced may be neglected or tolerated and some are not acceptable, it must be eliminated for better functioning of the parts.

Types

Casting defects can be categorized into 5 types

1. Gas Porosity: Blowholes, open holes, pinholes
2. Shrinkage defects: shrinkage cavity
3. Mold material defects: Cut and washes, swell, drops, metal penetration, rat tail
4. Pouring metal defects: Cold shut, misrun, slag inclusion
5. Metallurgical defects: Hot tears, hot spot.

The various casting defects that appear in the casting process are

The defect caused due to misalignment of upper and lower part of the casting and misplacement of the core at parting line.
Cause:
(i) Improper alignment of upper and lower part during mold preparation.
(ii) Misalignment of flask (a flask is type of tool which is used to contain a mold in metal casting. it may be square, round, rectangular or of any convenient shape.)
Remedies
(i) Proper alignment of the pattern or die part, molding boxes.
(ii) Correct mountings of pattern on pattern plates.
(iii) Check the alignment of flask.

It is the enlargement of the mold cavity because of the molten metal pressure, which results in localised or overall enlargement of the casting.
Causes
(i) Defective or improper ramming of the mold.
Remedies
(i) The sand should be rammed properly and evenly.

When gases entrapped on the surface of the casting due to solidifying metal, a rounded or oval cavity is formed called as blowholes. These defects are always present in the cope part of the mold.
Causes
(i) Excessive moisture in the sand.
(ii) Low Permeability of the sand.
(iii) Sand grains are too fine.
(iv) Too hard rammed sand.
(v) Insufficient venting is provided.
Remedies
(i) The moisture content in the sand must be controlled and kept at desired level.
(ii) High permeability sand should be used.
(iii) Sand of appropriate grain size should be used.
(iv) Sufficient ramming should be done.
(v) Adequate venting facility should be provided.

Drop defect occurs when there is cracking on the upper surface of the sand and sand pieces fall into the molten metal.
Causes
(i) Soft ramming and low strength of sand.
(ii) Insufficient fluxing of molten metal. Fluxing means addition of a substance in molten metal to remove impurities. After fluxing the impurities from the molten metal can be easily removed.
(iii) Insufficient reinforcement of sand projections in the cope.
Remedies
(i) Sand of high strength should be used with proper ramming (neither too hard nor soft).
(ii) There should be proper fluxing of molten metal, so the impurities present in molten metal is removed easily before pouring it into the mold.
(iii) Sufficient reinforcement of the sand projections in the cope.

These casting defects appear as an uneven and rough surface of the casting. When the size of sand grains is larges, the molten fuses into the sand and solidifies giving us metal penetration defect.
Causes
(i) It is caused due to low strength, large grain size, high permeability and soft ramming of sand. Because of this the molten metal penetrates in the molding sand and we get rough or uneven casting surface.
Remedies
(ii) This defect can be eliminated by using high strength, small grain size, low permeability and soft ramming of sand.

They are very small holes of about 2 mm in size which appears on the surface of the casting. This defect happens because of the dissolution of the hydrogen gases in the molten metal. When the molten metal is poured in the mold cavity and as it starts to solidify, the solubility of the hydrogen gas decreases and it starts escaping out the molten metal leaves behind small number of holes called as pinholes.
Causes
(i) Use of high moisture content sand.
(ii) Absorption of hydrogen or carbon monoxide gas by molten metal.
(iii) Pouring of steel from wet ladles or not sufficiently gasified.
Remedies
(i) By reducing the moisture content of the molding sand.
(ii) Good fluxing and melting practices should be used.
(iii) Increasing permeability of the sand.
(iv) By doing rapid rate of solidification.

The formation of cavity in the casting due to volumetric contraction is called as shrinkage cavity.
Causes
(i) Uneven or uncontrolled solidification of molten metal.
(ii) Pouring temperature is too high.
Remedies
(i) This defect can be removed by applying principle of directional solidification in mold design.
(ii) Wise use of chills (a chill is an object which is used to promote solidification in a specific portion of a metal casting) and padding.

It is a type of surface defects and a line on the surface can be seen. When the molten metal enters into the mold from two gates and when these two streams of molten metal meet at a junction with low temperatures than they do not fuse with each other and solidifies creating a cold shut (appear as line on the casting). It looks like a crack with round edge.
Causes
(i) Poor gating system
(ii) Low melting temperature
(iii) Lack of fluidity
Remedies
(i) Improved gating system.
(ii) Proper pouring temperature.

When the molten metal solidifies before completely filling the mold cavity and leaves a space in the mold called as misrun.
Causes
(i) Low fluidity of the molten metal.
(ii) Low temperature of the molten metal which decreases its fluidity.
(iii) Too thin section and improper gating system.
Remedies
(i) Increasing the pouring temperature of the molten metal increases the fluidity.
(ii) Proper gating system
(iii) Too thin section is avoided.

This defect is caused when the molten metal containing slag particles is poured in the mold cavity and it gets solidifies.
Causes
(i) The presence of slag in the molten metal
Remedies
(i) Remove slag particles form the molten metal before pouring it into the mold cavity.

when the metal is hot it is weak and the residual stress (tensile) in the material cause the casting fails as the molten metal cools down. The failure of casting in this case is looks like cracks and called as hot tears or hot cracking.
Causes
(i) Improper mold design.
Remedies
(i) Proper mold design can easily eliminate these types of casting defects.
(ii) Elimination of residual stress from the material of the casting.

Hot spot defects occur when an area on the casting cools more rapidly than the surrounding materials. Hot spot are areas on the casting which is harder than the surrounding area. It is also called as hard spot.
Causes
(i) The rapid cooling an area of the casting than the surrounding materials causes this defect.
Remedies
(i) This defect can be avoided by using proper cooling practice.
(ii) By changing the chemical composition of the metal.

It is the holes created on the external surface or inside the casting. It occurs when loose sand washes into the mold cavity and fuses into the interior of the casting or rapid pouring of the molten metal.
Causes:
(i) Loose ramming of the sand.
(ii) Rapid pouring of the molten metal into the mold results in wash away of sand from the mold and a hole is created.
(iii) Improper cleaning of the mold cavity.
Remedies
(i) Proper ramming of the sand.
(ii) Molten metal should be poured carefully in the mold.
(iii) Proper cleaning of the molten cavity eliminates sand holes.

The embedding of particles of dust and sand in the casting surface, results in dirt defect.
Causes:
(i) Cursing of mold due to improper handling and Sand wash (A sloping surface of sand that spread out by stream of molten metal).
(ii) Presence of slag particles in the molten metal.
Remedies:
(i) Proper handling of the mold to avoid crushing.
(ii) Sufficient fluxing should be done to remove slag impurities from molten metal.

It is an external defect in which there is a number of small cavities in close proximity present in the metal casting.
Causes:
(i) It is caused due to dirt and scurf held mechanically in the suspension of the molten metal.
(ii) Due to imperfect skimming in the ladle.
Remedies
(i) Prevent the entry of dirt and scurf in the molten metal.
(ii) Prevent sand wash.
(iii) Remove slag materials from the molten metal by proper skimming in the ladle.

It is an accidental and unwanted deformation in the casting that happens during or after solidification. Due to this defect, the dimension of the final product changes.
Causes:
(i) Due to different rates of solidification of different sections. This induces stresses in adjoining walls and result in warpage.
(ii) Large and flat sections or intersecting section such as ribs are more prone to these casting defects.
Remedies
(i) It can be prevented by producing large areas with wavy, corrugated construction, or add sufficient rib-like shape, to provide equal cooling rates in all areas.
(ii) Proper casting designs can reduce these defects more efficiently.

A thin projection of metal, not considered as a part of casting is called as fins or fin. It is usually occurs at the parting of the mold or core section.

Causes:

(i) Incorrect assembling of mold and cores.
(ii) Insufficient weight of the mold or improper clamping of the flask may produce the fins.
Remedies
(i) Correct assembly of the mold and cores.
(ii) There should be sufficient weight on the top part of the mold so that the two parts fit together tightly.

Here we have discussed about what is casting defects - types, causes and remedies to eliminate it. If you like this post than dont forget to share it on google+ and Facebook. If you find any query regarding this post feel free to ask.

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What is Casting Defects - Types, Causes and Remedies? - Mechanical Booster

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It is an unwanted irregularities that appear in the casting during metal casting process. There is various reason or sources which is responsible for the defects in the cast metal. Here in this section we will discuss all the major types of casting defects.

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Cold shut
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VIM Gas Atomization Aubert & Duval metal powders

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For additional information, visit: http://bit.ly/QYucWp and don't forget to subscribe to our channel here http://www.youtube.com/user/MechanicsTips -------------------------------------------------------------------- Covered Points: - Metal powder. - Steps of manufacturing metal powder. - Methods of shaping metal powder. - mechanical pressing, injection moulding and isostatic pressing .

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Rolling - Industrial Process - Mechanical

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GROUP 7

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