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    Casting Defects

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    vraj_h_thakar
    This document discusses various casting defects including shifts, fins, warpage, blow holes, sand holes, shrinkage cavities, cold shuts, pin holes, inclusions, swell, scrabs, and hot tears. It describes the causes and ways to prevent these defects. Non-destructive testing methods like visual inspection, radiography, and ultrasonic testing are outlined to inspect castings for internal and external defects.

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    Casting Defects

    Uploaded by

    vraj_h_thakar
    397 views20 pages
    This document discusses various casting defects including shifts, fins, warpage, blow holes, sand holes, shrinkage cavities, cold shuts, pin holes, inclusions, swell, scrabs, and hot tears. It describes the causes and ways to prevent these defects. Non-destructive testing methods like visual inspection, radiography, and ultrasonic testing are outlined to inspect castings for internal and external defects.

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    This document discusses various casting defects including shifts, fins, warpage, blow holes, sand holes, shrinkage cavities, cold shuts, pin holes, inclusions, swell, scrabs, and hot tears. It describes the causes and ways to prevent these defects. Non-destructive testing methods like visual inspection, radiography, and ultrasonic testing are outlined to inspect castings for internal and external defects.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    397 views20 pages

    Casting Defects

    Uploaded by

    vraj_h_thakar
    This document discusses various casting defects including shifts, fins, warpage, blow holes, sand holes, shrinkage cavities, cold shuts, pin holes, inclusions, swell, scrabs, and hot tears. It describes the causes and ways to prevent these defects. Non-destructive testing methods like visual inspection, radiography, and ultrasonic testing are outlined to inspect castings for internal and external defects.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
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    CASTING DEFECTS

    SHIFTS:-This is a external defect in casting.


    -It is caused due to core misplacement or mismatching of top & bottom parts of casting at a parting line. -It can be prevented by ensuring proper alignment of die part, moulding boxes, correct mounting of pattern on pattern plates like pin before use.
    -

    FIN:-A thin projection of metal, not intended as a part


    of casting , is called fin. -Moulds & cores incorrectly assembled will cause fin. -This defect occur at parting of mould or core section. -It can be prevented by using sufficient weight on top part of mould so that two parts fit tightly together.

    WARPAGE:-It is unintentional & undesirable deformation in casting that occurs during or after solidification. -Due to different rates of solidification different section of casting, stresses are set up in adjoining walls & resulting in warpage in those areas. -It can be prevented by producing large areas with wavy, corrugated construction, or add sufficient ribs or to provide equal cooling rates in all areas.

    BLOW HOLES:-Blow holes are round holes appearing in the form


    of cluster of large no. of holes below the surface of casting. -Blow holes are caused by excessive moisture in sand, excessive use of organic binders, sand is rammed too hard, moulds inadequately vented etc. -It can be prevented by well adjusting moisture content in sand, using proper grain size of sand, ramming should not too hard & venting should be adequate.

    SAND HOLES:-Sand holes are found on external surface or inside the casting. -They are caused by loose sand washing into mould cavity & fusing into interior of casting. -It can be prevented by proper cleaning of mould & careful pouring of molten metal.

    SHRINKAGE CAVITY:-Shrinkage cavity is a void or depression in casting caused mainly by uncontrolled & haphazard solidification of metal. -It can be prevented by applying principle of directional solidification in mould design & by judicious use of chills, padding, etc.

    COLD SHUT:-A cold shut is external defect of casting.


    -It formed due to imperfect fusion of two steam of metal in mould cavity or unequal section of pattern assembled together. -This defect may appear like a crack or seam with rounded edges. -It can be eliminated by using hotter metal, frequent inspection & replacement of pattern.

    PIN HOLES:-Pinholes are numerous small holes, usually visible on surface of casting cleaned by shot blasting. -They are caused by sand with high moisture content, absorption of H2 or CO2 gases. -It can be minimized by using good melting & fluxing practices, by reducing moisture content of moulding sand & by promoting rapid rate of solidification.

    INCLUSIONS:-Any separate non-metallic foreign material


    present in cast metal is called inclusion. -These inclusion may be in the form of oxides, slag, dirt & gas. -It can be prevented by entering of proper fluxing & effective skimming. Also prevented by promoting oxides metal may be confined to minimum by proper pouring & gating system.

    SWELL:-Swell is the enlargement of mould cavity by metal pressure. -It is caused by improper or defective ramming of the mould. -It can be prevented by ramming of sand should be properly & evenly.

    SCRABS:-Scrabs are sort of projection on casting that occur when portion of face of mould or core lift & metal flow underneath in thin layer.

    -Scrabs can be identified as rough, irregular projection on surface containing embedded sand.
    -It can be eliminated by mixing additives such as wood flour, sea coal into sand.

    HOT TEARS:-It has internal or external cracks having ragged edges occurring immediately after metal has solidifies.
    -It may be produced if casting is poorly designed & abrupt sectional changes take place, no proper fillet & corner radii are provided. -It can be eliminated by improving design, proper directional solidification, rate of cooling, correct pouring temperature & control of mould hardness.

    INSPECTION OF CASTING:& external defects in it.


    -Inspection of casting is done to detect the internal

    -there are classified into two parts;

    (1)DESTRUCTIVE TESTING (2)NON-DESTRUCTIVE TESTING

    -DESTRUCTIVE TESTING:It includes picking up few sample, cutting them pieces where defects are suspected & examined their sectioned surface to find out internal defects.

    -NON-DESTRUCTIVE TESTING:-There are another classified into; (1)VISUAL INSPECTION (2)DIMENSIONAL INSPECTION (3)SOUND TEST (4)IMPACT TEST (5)PRESSURE TEST (6)RADIOGRAPHY TEST (7)MAGNETIC PARTICLE TEST (8)PENETRANT TEST (9)ULTRASONIC TEST

    -VISUAL INSPECTION:-It comprises of inspecting the surface of casting either with naked eye or sometimes with the help of magnifying glass or suitable microscope.
    -Almost all castings are subjected to some form of visual test. -The use of this method is confined to those defects only which appear on surface visualize blows, swells, surface cracks, shrinkages, surface porosity etc.

    -RADIOGRAPHY TEST:-Radiographic test involve the use of light rays of relatively shorter wave lengths. -The rays used for this purpose are x-ray & -rays. -The portion of the casting where defects are suspected, is exposed to x-rays. A cassette containing an x-ray film is placed behind & in contact with casting perpendicular to the rays. During exposure, the x-ray penetrate the casting & thus affect x-ray film.

    -Since most of defects like blow holes, porosities, cracks etc. are less dense than the sound metal of casting, they transmit x-rays better than sound, metal does. So film appears to be more dark where defects are in line of x-ray beam. -A better penetration through metal is obtained by using -rays on account of shorter wave length. --rays are used where x-ray can not be used. --rays are emitted by both Radium & Cobalt 60.

    -ULTRASONIC TESTING:-It is more sensitive method & is capable of revealing the internal defects of casting. -It is based on principle of reflection & transmission of high frequency sound waves. -Test consists of producing an ultrasonic sound & passing its wave through casting.

    -Wherever continuity of casting will break due to crack or void the sound wave will be reflected from there, otherwise wave will be reflected back only after travelling through the whole of the cutting. In this two cases time taken by the wave in returning will differ. This is recorded on an Oscillograph.

    -The various length of time so obtained will reveal the exact location of defect & also the extent to which it is present.

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