Flow Porosity

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1 casting. This can be achieved
by increasing the temperature
or velocity of the metal,
ensuring a smooth and
Flow Porosity consistent flow pattern, and
designing an appropriate
Flow porosity is a common casting gating system. Vacuum or
defect that occurs when there are pressure casting techniques
voids or spaces (porosity) between can also help to minimize
the solidified metal flows. This defect porosity by improving the flow
can weaken the final product and of molten metal into the mold
affect its overall quality. The main and reducing the chances of
cause of flow porosity is the air entrapment.
inadequate flow of molten metal
during casting, which can result from In some cases, adjusting the
several factors. alloy composition or modifying
the pouring rate may also help
One of the primary causes of flow to prevent flow porosity. By
porosity is a slow or cold metal flow, taking these steps,
which results in the metal solidifying manufacturers can produce
before it can completely fill the mold. high-quality castings that are
This can lead to the formation of free of defects and meet the
voids and spaces within the casting. desired specifications.
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Additionally, a poor flow pattern or
gating system design can cause
turbulence in the molten metal,
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leading to the entrapment of air and
the formation of porosity.
To prevent flow porosity, it is crucial

to optimize the metal flow during

Corrections:
The spaces between metal flows may appear on the

surface (as a hole) or inside (as porosity). The biggest
factor that contributes to this defect is the metal fill time.
It is essential to calculate and measure the fill time
accurately to ensure it is fast enough to fill the mold
completely. If there is any doubt, reducing the fill time as
much as possible is recommended.
 It is important to stabilize furnace operation and

reduce temperature variation to a maximum of +/-
10°F. Additionally, using the correct metal
temperature is crucial in preventing flow porosity. For
aluminum casting, it is essential to monitor the heat
loss in the ladle and shot sleeve and compensate for
it by adding more superheat to maintain the desired
metal temperature at the gate. This will help to
ensure a consistent flow of molten metal into the
mold and prevent the formation of voids and
porosity.

 To prevent flow porosity, it is important to stabilize the die temperature
during casting. Running the die at a higher temperature, typically above
400°F, can help to reduce thermal gradients and ensure a more uniform
solidification of the metal. This will help to prevent the formation of voids
and porosity, resulting in a higher quality casting.
 When it comes to preventing flow porosity, it is crucial to review and

correct the metal pressures during casting. The following steps can help
achieve this:
 Review the static metal pressure to ensure it meets the necessary

requirements. For zinc casting, the pressure should be above 2000 psi,
while for aluminum and magnesium, it should be above 3000 psi.
 Check the intensifier operation to ensure that it is functioning correctly.
 Consistency of pressure is critical for high-quality casting production.
 Evaluate and measure the rise time to ensure that the metal pressure is
quick enough. The optimal rise time will vary depending on the casting
shape.
 Ensure that the pressure setting is high enough to prevent porosity. A

final pressure of above 6000 psi is acceptable, but a pressure of above
9000 psi is ideal for best results.
 By reviewing and correcting the metal pressures during casting,

manufacturers can reduce the likelihood of flow porosity and produce
high-quality castings that meet or exceed the desired specifications.

Summary
Flow porosity is a casting defect that occurs when there is insufficient

metal flow, the metal is too cold, or there is a poor flow pattern, leading
to spaces or porosity between solidified metal flows. To correct this
defect, various measures can be taken, such as reducing the fill time,
stabilizing furnace and die temperatures, and ensuring that the metal
pressures are reviewed and corrected. Additionally, it is essential to use
the correct metal temperature and add more superheat to compensate
for heat loss in the ladle and shot sleeve in aluminum casting. By
implementing these corrections, manufacturers can reduce the likelihood
of flow porosity and produce high-quality castings that meet the desired
specifications.quality control of the casting process can also help to
prevent blisters and other defects from occurring.

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To prevent flow porosity, it is crucial

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The spaces between metal flows may appear on the

 It is important to stabilize furnace operation and

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 When it comes to preventing flow porosity, it is crucial to review and

 Review the static metal pressure to ensure it meets the necessary

 Check the intensifier operation to ensure that it is functioning correctly.

 Consistency of pressure is critical for high-quality casting production.

 Ensure that the pressure setting is high enough to prevent porosity. A

 By reviewing and correcting the metal pressures during casting,

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Flow porosity is a casting defect that occurs when there is insufficient

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