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    Casting Defects

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    VIBHAV
    The document discusses casting defects, including types, inspection methods, and causes of defects related to moulding, filling, and solidification. It also covers defects analysis and quality control. Common casting defects include flash, mismatch, cold shuts, blowholes, shrinkage cavities, and porosity.

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    Casting Defects

    Uploaded by

    VIBHAV
    15K views9 pages
    The document discusses casting defects, including types, inspection methods, and causes of defects related to moulding, filling, and solidification. It also covers defects analysis and quality control. Common casting defects include flash, mismatch, cold shuts, blowholes, shrinkage cavities, and porosity.

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    The document discusses casting defects, including types, inspection methods, and causes of defects related to moulding, filling, and solidification. It also covers defects analysis and quality control. Common casting defects include flash, mismatch, cold shuts, blowholes, shrinkage cavities, and porosity.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    15K views9 pages

    Casting Defects

    Uploaded by

    VIBHAV
    The document discusses casting defects, including types, inspection methods, and causes of defects related to moulding, filling, and solidification. It also covers defects analysis and quality control. Common casting defects include flash, mismatch, cold shuts, blowholes, shrinkage cavities, and porosity.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 9
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    The passage discusses different types of casting defects, how they can be classified, inspection methods, and analysis of defects.

    The main types of casting defects discussed are moulding-related defects like flash and mismatch, filling-related defects like cold shut and blowholes, and solidification-related defects like shrinkage and porosity.

    Casting defects can be classified based on location, type, size, process, cause, stage, and reparability.

    ME 333 Manufacturing Process I

    Lecture 09

    Casting Defects
    Types of Defects Inspection Methods Moulding Related Defects Filling Related Defects Solidification Related Defects Defects Analysis

    2006 Prof. B. Ravi, Mechanical Engineering Department, Indian Institute of Technology, Bombay.

    Types of Defects
    Based on Location: External Internal Based on Type: Geometric Integrity Based on Size/Severity: Small/Minor Large/Major Based on Process: Moulding-related Filling-related Solidification-related. Based on Cause: Raw materials Product design Tooling design Process parameters Process control Based on Stage: Casting Rough machining Finish machining Service Based on Reparability: Repairable Irreparable

    Inspection Methods
    Destructive: Sectioning, Machining Mechanical testing Chemical testing Non-Destructive: Visual: large external defects Dimensional: size defects Pressure testing: leakage Radiography: internal holes Ultrasound: internal discontinuities Eddy current: hardness, structure Magnetic Particle: sub-surface discontinuities Dye Penetrant: defects with opening to surface.

    Moulding-related Defects
    Improper Closure Across parting plane: flash Along parting line: mismatch

    FLASH

    MISMATCH
    [Atlas of Casting Defects, Institute of British Foundrymen]

    Filling-related Defects
    Incomplete Filling: cold shut, misrun. Gaseous Entrapments: blow hole, gas porosity. Solid Inclusions: sand inclusion, slag inclusion.
    [Atlas of Casting Defects, Institute of British Foundrymen]

    COLD SHUT

    MISRUN

    BLOW HOLE

    GAS POROSITY

    Solidification/Cooling-related Defects
    Solidification Shrinkage: cavity, porosity, centerline, sink. Hindered Cooling Contraction: hot tear, crack, distortion.
    SHRINKAGE CAVITY
    [Atlas of Casting Defects, Institute of British Foundrymen]

    POROSITY

    SINK

    CORNER SHRINKAGE

    CRACK

    Defects Analysis
    Individual Defect: Defect identification Cause identification Remedy specification Defects over a batch/period: Quality control charts Defect frequency (histogram) Defect spectrum (pattern over time) Expert Systems for Defects Analysis Knowledge base (IF-THEN rules with confidence) Inference Engine

    Summary
    Casting defects are significant: typically 1-10% About 20 major types of casting defects:
    Flash, mismatch, cold shut, misrun, blow hole, gas porosity, shrinkage cavity, porosity, centerline, sink, hot tear, crack, scab, swell, metal penetration, rough surface. Other defects: improper composition and properties.

    Implications:
    Minor defects can be repaired, with cost increase. Major defects lead to rejection, with loss of productivity.

    Status and Progress:


    Quality control and defects analysis: experts/systems. Quality certification and assurance gaining importance. Responsibility shifting to manufacturer; legal implications. Toward zero defects: prevention is better than cure!

    Home Exercise
    Draw the cause-effect (Ishikawa) diagram for the following defects: Shrinkage porosity, Blow hole, Mismatch. Include causes related to moulding, filling and solidification. For each of above group of causes, identify the sub-causes (ex. improper filling), and sub-sub-causes (ex. ingate too small). Write the IF-THEN rules for identifying and troubleshooting (cause) the following defects: shrinkage porosity, gas porosity.

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