Casting

Objective

History
Definition of casting
Advantages
Basic features
Types of Casting
Casting Materials & Grades
Disadvantages & Casting Defects
Inspection
Casting Cost Estimation

It is oldest
manufacturing
process.

Casting:
Castingisamanufacturingprocessbywhichaliquidmaterialisusually
pouredintoamold,whichcontainsahollowcavityofthedesiredshape,
andthenallowedtosolidify.Thesolidifiedpartisalsoknownasacasting,
whichisejectedorbrokenoutofthemoldtocompletetheprocess
Castingmaterialsareusuallymetalsorvariouscoldsettingmaterials
thatcureaftermixingtwoormorecomponentstogether;examples
areepoxy,concrete,plasterandclay.Castingismostoftenusedfor
makingcomplexshapesthatwouldbeotherwisedifficultoruneconomical
tomakebyothermethods
Castingprocesscanbedividedintotwobasiccategories:1.Thoseforwhichanewmoldmustbecreatedforcasting(the
expandable-moldprocesses)
2.Thosethatemployapermanent,reusablemold(thenonexpandable-moldprocesses)

WHY CASTING..!!!!!

AdvantagesofCasting:
1.OnBasisofSizeofObjecttobeManufactured:
Sizeofcastobjectsvaryoverlargerange.Anobjectfrom5gmto200tonn,
anythingcanbecast.
2.OnBasisofComplexity:
Castingcanbeeffectivelyusedforcomplexshapedobjects.Itcanwork
wheregeneralmachiningprocessescannotbeused,asincomplicated
innerandoutershapesofobject.
3.WeightSaving:
Componentmadewithcastingprocessislighterthanthecomponentmade
withothermachiningprocesses.
4.ControlOverTheProcess:
Castingprovidesversatility.Widerangeofpropertiescanbeattainedby
adjustingpercentageofalloyingelements.

5.Accuracy:
Castingcanbemadewithhairlikeprecisionprovidedpropermoldingand
castingtechniqueisemployed.
6.FibrousStructure:
Onlycastinghavethisadvantage.Castingleavescomponentwithitssolid
fibrousstructurewhichinheritgreatcompressivestrength.So,component
subjectedtocompressivestrengtharemadewithcastingegICengine
cylinder.
7.ControlOverGrainSize:
Grainsizeofcastcomponentcanbeeasilycontrolledbycontrolling
coolingratewhichinturncanbeusedtomodifytheproperties.
8.LowCost:
Casingisoneofcheapestmethodformassproduction.

Basic Features
Pattern: A pattern is made of wood or metal, is a replica of the
final product and is used for preparing mold cavity
Riser: A column of metal placed in the mold to feed the casting
as it shrinks and solidifies. Also known as a "feed head."
Runner: The channel through which the molten metal is carried
from the sprue to the gate.
Cores: A separated part of the mold, made of sand and
generally baked, which is used to create openings and various
shaped cavities in the casting.
Gate: A channel through which the molten metal enters the
casting cavity.

Parting Line: Joint where mold separates to permit removal of the

pattern and which shows how and where to open the mold.

Sand: A sand which binds strongly without losing its permeability to

air or gases.

Chaplet: A metal support used to hold a core in place in a mold. Not

used when a core print will serve.

Binders: Materials used to hold molding sand together.

Pouring basin: Filling the mold with molten metal.

Shrinkage: The decrease in volume when molten metal solidifies.

Mould: The mould contains a cavity whose geometry determines the

shape of cast part.
Mold material should posses refractory characteristics and with
stand the pouring temperature

Typesofcasting!!!
Followingarethebasictypesofcasting..:
Sandcasting
Diecasting
Shellmoldcasting
Permanentmoldcasting
Investmentcasting(lostwaxcasting)
Lost-foamcasting
Centrifugalcasting

SANDCASTING
Sandcasting,alsoknownassandmoldedcasting,isametal
castingprocesscharacterizedbyusingsandasthemoldmaterial.Theterm
"sandcasting"canalsorefertoanobjectproducedviathesandcasting
process.Sandcastingsareproducedin
specializedfactoriescalledfoundries.Over70%ofallmetalcastingsare
producedviaasandcastingprocess
Sandcastingisrelativelycheapandsufficientlyrefractoryevenforsteel
foundryuse.Inadditiontothesand,asuitablebondingagent(usuallyclay)
ismixedoroccurswiththesand.Themixtureismoistened,typicallywith
water,butsometimeswithothersubstances,todevelopstrengthand
plasticityoftheclayandtomaketheaggregatesuitableformolding.The
sandistypicallycontainedinasystemofframesormoldboxesknownas
aflask.Themoldcavitiesandgatesystemarecreatedbycompactingthe
sandaroundmodels,orpatterns,orcarveddirectlyintothesand.

Basicprocess
Therearesixstepsinthisprocess:
1.Placeapatterninsandtocreateamold.
2.Incorporatethepatternandsandinagating
system.
3.Removethepattern.
4.Fillthemoldcavitywithmoltenmetal.
5.Allowthemetaltocool.
6.Breakawaythesandmoldandremovethe
casting

Diecasting
Diecastingisametalcastingprocessthatischaracterizedby
forcingmoltenmetalunderhighpressureintoamoldcavity.Themold
cavityiscreatedusingtwohardenedtoolsteeldieswhichhavebeen
machinedintoshapeandworksimilarlytoaninjectionmoldduringthe
process.Mostdiecastingsaremadefromnon-ferrousmetals,
specificallyzinc,copper,aluminum,magnesium,lead,pewterandtin
basedalloysDependingonthetypeofmetalbeingcast,ahot-orcoldchambermachineisused.
Thecastingequipmentandthemetaldiesrepresentlargecapitalcostsand
thistendstolimittheprocesstohighvolumeproduction.Manufactureof
partsusingdiecastingisrelativelysimple,involvingonlyfourmainsteps,
whichkeepstheincrementalcostperitemlow.Itisespeciallysuitedfora
largequantityofsmalltomediumsizedcastings,whichiswhydiecasting
producesmorecastingsthananyothercastingprocess.Diecastingsare
characterizedbyaverygoodsurfacefinish(bycastingstandards)and
dimensionalconsistency

 Castmetals:
Themaindiecastingalloysare:zinc,aluminum,magnesium,copper,lead,&tin;
althoughuncommon,ferrous
Thefollowingisasummaryoftheadvantagesofeachalloy:
Zinc:theeasiestmetaltocast;highductility;highimpactstrength;easilyplated;
economicalforsmallparts;promoteslongdielife.
Aluminum:lightweight;highdimensionalstabilityforcomplexshapesandthinwalls;
goodcorrosionresistance;goodmechanicalproperties;highthermalandelectrical
conductivity;retainsstrengthathightemperatures.
Magnesium:theeasiestmetaltomachine;excellentstrength-to-weightratio;lightest
alloycommonlydiecast.
Copper:highhardness;highcorrosionresistance;highestmechanicalpropertiesof
alloysdiecast;excellentwearresistance;excellentdimensionalstability;strength
approachingthatofsteelparts.
Leadandtin:highdensity;extremelyclosedimensionalaccuracy;usedforspecial
formsofcorrosionresistance.Suchalloysarenotusedinfoodserviceapplications
forpublichealthreasons.Typemetal,analloyofLead,TinandAntimony(with
sometimestracesofCopper)isusedforcastinghandsettypeinletterpressprintingand
hotfoilblocking.

 Equipment:
Therearetwobasictypesofdiecastingmachines:
hot-chambermachines&cold-chambermachines.
Theseareratedbyhowmuchclampingforcetheycanapply.Typical
ratingsarebetween2,500and25,000kg.

Dies:
Twodiesareusedindiecasting;oneiscalledthe"coverdiehalf"
andtheotherthe"ejectordiehalf".Wheretheymeetiscalledthe
partingline.Thecoverdiecontainsthesprue(forhot-chamber
machines)orshothole(forcold-chambermachines),whichallows
themoltenmetaltoflowintothedies;thisfeaturematchesupwith
theinjectornozzleonthehot-chambermachinesortheshot
chamberinthecold-chambermachines.Theejectordiecontainsthe
ejectorpinsandusuallytherunner,whichisthepathfromthesprue
orshotholetothemoldcavity.Thecoverdieissecuredtothe
stationary,orfront,platenofthecastingmachine,whiletheejector
dieisattachedtothemovableplaten.Themoldcavityiscutinto
twocavity inserts,whichareseparatepiecesthatcanbereplaced
relativelyeasilyandboltintothediehalves

Theejectordiehalf:

Thecoverdiehalf:

Process:
The following are the four steps intraditional die casting, also
known ashigh-pressure die casting,
these are also the basis for any of the die casting
variations.
1.
2.
3.
4.

Die preparation,
Filling,
Ejection,
Shakeout

 Advantagesanddisadvantages:
Advantagesofdiecasting:
Excellentdimensionalaccuracy(dependentoncastingmaterial,buttypically0.1mm
forthefirst2.5cm(0.005inchforthefirstinch)and0.02mmforeachadditional
centimeter(0.002inchforeachadditionalinch).
Smoothcastsurfaces(Ra12.5micrometresor0.040.10thou).
Reducesoreliminatessecondarymachiningoperations.
Rapidproductionrates.
Castingoflowfluiditymetals.

Themaindisadvantagetodiecastingistheveryhighcapitalcost.Boththe
castingequipmentrequiredandthediesandrelatedcomponentsarevery
costly,ascomparedtomostothercastingprocesses.Thereforetomakedie
castinganeconomicprocessalargeproductionvolumeisneeded.Other
disadvantagesarethattheprocessislimitedtohigh-fluiditymetals,and
castingweightsmustbebetween30grams(1oz)and10kg(20lb).Inthe
standarddiecastingprocessthefinalcastingwillhaveasmallamountof
porosity.Thispreventsanyheattreatingorwelding,becausetheheatcauses
thegasintheporestoexpand,whichcausesmicro-cracksinsidethepartand
exfoliationofthesurface.

Shell molding
Shell molding, also known asshell-mold casting,is an
expendable moldcastingprocess that uses aresincoveredsandto
form themold.
Shell mold casting allows the use of both ferrous and non-ferrous
metals, most commonly using cast iron, carbon steel, alloy steel,
stainless steel, aluminum alloys, & copper alloys. Typical parts
are small-to-medium in size and require high accuracy, such as gear
housings, cylinder heads, connecting rods, & lever arms

Process
1.
2.
3.
4.
5.
6.

Patterncreation
Moldcreation
Moldassembly
Pouring
Cooling
Castingremoval

Examplesofshellmoldeditemsincludegear
housings,cylinderheads&connectingrods.It
isalsousedtomakehigh-precisionmolding
cores

 Advantagesanddisadvantages:
Oneofthegreatestadvantagesofthisprocessisthatitcanbecompletely
automatedformassproduction.Thehighproductivity,lowlaborcosts,
goodsurfacefinishes,andprecisionoftheprocesscanmorethanpayfor
itselfifitreducesmachiningcosts.
Therearealsofewproblemsduetogases,becauseoftheabsenceof
moistureintheshell,andthelittlegasthatisstillpresenteasilyescapes
throughthethinshell.Whenthemetalispouredsomeoftheresinbinder
burnsoutonthesurfaceoftheshell,whichmakesshakingouteasy.

Permanentmoldcasting:
Permanentmoldcastingismetalcastingprocessthatemploys
reusablemolds("permanentmolds"),usuallymadefrommetal.Themost
commonprocessusesgravitytofillthemold,howevergaspressureor
avacuumarealsoused.Avariationonthetypicalgravitycastingprocess,
calledslushcasting,produceshollowcastings.Commoncastingmetals
arealuminum,magnesium,andcopperalloys.Othermaterialsinclude
tin,zinc,andleadalloysandironandsteelarealsocastingraphitemolds.
Therearefourmaintypesofpermanentmoldcasting:
1. gravity,
2. slush,
3. low-pressure,
4. vacuum.

StepsinPermanentMoldCasting:
1) Moldispreheatedandcoated;
2) Core(ifused)areinsertedandmoldisclosed;
3) Moltenmetalispouredintothemold;
4) Moldisopened.Finishedpartsisshownin5

 Advantagesanddisadvantages:
Themainadvantagesarethereusablemold,goodsurfacefinish&good
dimensionalaccuracy

1.
2.
3.

Therearethreemaindisadvantages:
high tooling cost,
limitedtolow-melting-pointmetals,
shortmoldlife

Investmentcasting
Investmentcastingisanindustrialprocessbasedonandalso
calledlost-wax casting,oneoftheoldestknownmetal-forming
techniques.From5,000yearsago,whenbeeswaxformedthepattern,
totodayshigh-technologywaxes,refractorymaterialsandspecialist
alloys,thecastingsallowtheproductionofcomponentswithaccuracy,
repeatability,versatilityandintegrityinavarietyofmetalsandhighperformancealloys.
Theprocessisgenerallyusedforsmallcastings,buthasbeenusedto
producecompleteaircraftdoorframes,steelcastingsofupto300kg
(660lbs)andaluminiumcastingsofupto30kg(66lbs).It is
generally more expensive per unit than die casting or sand casting,but
haslowerequipmentcosts.Itcanproducecomplicatedshapesthat
wouldbedifficultorimpossiblewithdiecasting,yetlikethatprocess,
itrequireslittlesurfacefinishingandonlyminormachining..

Processes:
1) Wax pattern are produced
2) Several pattern are attached to
a sprue to form a pattern tree;
3) The pattern tree is coated with
a thin layer of refractory
material;
4) The full mold is formed by
covering the coated tree with
sufficient refractory material;
5) The mold is held in an inverted
position and heated to met the
wax and permit it to drip out of
the cavity;
6) The mold is preheated to high
temperature, which Ensures
that all contaminants are
eliminated from the mold; it
also permits the liquid metal to
flow more easily into the
detailed cavity; the molten
metal is poured; it solidifies and
7) The mold is broken away from
the finished casting. Parts are

 Theinvestmentshellforcastingaturbochargerrotor:

AdvantagesofInvestmentcasting:
Averysmoothsurfaceisobtainedwithnopartingline.
Dimensionalaccuracyisgood.
Certainunmachinablepartscanbecasttopreplannedshape .

DisadvantagesofInvestmentcasting:
Thisprocessisexpensive,isusuallylimitedtosmallcasting,andpresents
somedifficultieswherecoresareinvolved.
Holescannotbesmallerthan1/16in.(1.6mm)andshouldbenodeeper
thanabout1.5timesthediameter.
Investmentcastingsrequireverylongproduction-cycletimesversusother
castingprocesses.
Thisprocessispracticallyinfeasibleforhigh-volumemanufacturing,due
toitshighcostandlongcycletimes.

Applications:
Investmentcastingisusedintheaerospaceandpower
generationindustriestoproduceturbine blades with complex shapes or
cooling systems

Lost-foamcasting
Lost-foamcasting(LFC)isatypeofevaporative-patterncastingprocess
thatissimilartoinvestmentcastingexceptfoamisusedfor
thepatterninsteadofwax.
Thisprocesstakesadvantageofthelowboilingpointoffoamtosimplify
theinvestmentcastingprocessbyremovingtheneedtomeltthewaxoutof
themold

Processes
1. Pattern making
molded expanded polystyrene
can be assembled from multiple
pieces
coated with porous refractory
2. Mold formation
pattern surrounded by loose sand
sand compacted by vibration
3. Metal pour
liquid metal poured directly into
pattern

Advantages
Thiscastingprocessisadvantageousforverycomplexcastingsthatwould
regularlyrequirecores.
Itisalsodimensionallyaccurate,maintainsanexcellentsurfacefinish,
requiresnodraft,andhasnopartinglinessonoflashisformed.
Ascomparedtoinvestmentcasting,itischeaperbecauseitisasimpler
processandthefoamischeaperthanthewax.
Risersarenotusuallyrequiredduetothenatureoftheprocess;becausethe
moltenmetalvaporizesthefoamthefirstmetalintothemoldcoolsmore
quicklythantherest,whichresultsinnaturaldirectionalsolidification
Foamiseasytomanipulate,carveandglue,duetoitsuniqueproperties
Disadvantages
Thetwomaindisadvantagesarethatpatterncostscanbehighforlow
volumeapplicationsandthepatternsareeasilydamagedordistorteddueto
theirlowstrength.
Ifadieisusedtocreatethepatternsthereisalargeinitialcost.

Centrifugalcasting
Centrifugalcastingorroto-castingisacastingtechniquethatistypically
usedtocastthin-walledcylinders.Itisnotedforthehighqualityoftheresults
attainable,particularlyforprecisecontroloftheirmetallurgyandcrystal
structure.Unlikemostothercastingtechniques,centrifugalcastingischiefly
usedtomanufacturestockmaterialsinstandardsizesforfurthermachining.

Process:
Incentrifugalcasting,apermanentmoldis
rotatedcontinuouslyaboutitsaxisathigh
speeds(300to3000rpm)asthemoltenmetal
ispoured.Themoltenmetaliscentrifugally
throwntowardstheinsidemoldwall,where
itsolidifiesaftercooling.
Castingmachinesmaybeeither horizontal
or vertical-axis.Horizontalaxismachines
arepreferredforlong,thincylinders,vertical
machinesforrings.

Featuresofcentrifugalcasting:
Castingscanbemadeinalmostanylength,thickness&diameter.
Differentwallthicknessescanbeproducedfromthesamesizemold.
Eliminatestheneedforcores.
Resistanttoatmosphericcorrosion,atypicalsituationwithpipes.
Mechanicalpropertiesofcentrifugalcastingsareexcellent
Onlycylindricalshapescanbeproducedwiththisprocess.
Materials:
Typicalmaterialsthatcanbecastwiththisprocessareiron,steel,stainless
steels,glass,andalloysofaluminum,copper&nickel.
Twomaterialscanbecasttogetherbyintroducingasecondmaterialduringthe
process.
Applications:
Typicalpartsmadebythisprocessarepipes,boilers,pressurevessels
,flywheels,cylinderlinersandotherpartsthatareaxi-symmetric.Itis
notablyusedtocastcylinderlinersandsleevevalvesforpistonengines,parts
whichcouldnotbereliablymanufacturedotherwise.

Casting Material & Grades

Common

ASTM

Designation

Casting Specification

Carbon Steel

ASTM A216
Grade WCB

Low Temp

ASTM A352

Carbon Steel

Grade LCB

Low Temp

ASTM A352

Carbon Steel

Grade LC1

Low Temp

ASTM A352

Carbon Steel

Grade LC2

3.1/2% Nickel

ASTM A352

Steel

Grade LC3

1.1/4%Chrome

ASTM A217

1/2% Moly Steel

Grade WC6

2.1/4%Chrome

ASTM A217
Grade C9

5%Chrome

ASTM A217

1/2% Moly

Grade C5

9%Chrome

ASTM A217

1% Moly

Grade C12

12% Chrome

ASTM A487

Steel

Grade CA6NM

12% Chrome

ASTM A217
Grade CA15

Service Recommendations

Non-corrosive applications including water, oil and gases at temperatures between

-20F (-30C) and +800F (+425C)
Low temperature applications to -50F (-46C). Not for use above +650F (+340C).

Low temperature applications to -75F (-59C). Not for use above +650F (+340C).

Low temperature applications to -100F (-73C). Not for use above +650F
(+340C).
Low temperature applications to -150F (-101C). Not for use above +650F
(+340C).
Non-corrosive applications including water, oil and gases at temperatures between
-20F (-30C) and +1100F (+593C).
Non-corrosive applications including water, oil and gases at temperatures between
-20F (-30C) and +1100F (+593C).
Mild corrosive or erosive applications as well as non-corrosive applications at
temperatures between -20F (-30C) and +1200F (+649C).

Mild corrosive or erosive applications as well as non-corrosive applications at

temperatures between -20F (-30C) and +1200F (+649C).

Corrosive application at temperatures between -20F (-30C) and +900F (+482C).

Corrosive application at temperatures up to +1300F (+704C)

Common

ASTM

Designation

Casting Specification

316SS

ASTM A351
Grade CF8M

347SS

ASTM 351
Grade CF8C

304SS

ASTM A351
Grade CF8

304L SS

ASTM A351

Service Recommendations

Corrosive or either extremely low or high temperature non-corrosive services between -450F (268C) and +1200F (+649C). Above +800F (+425C) specify carbon content of 0.04% or
greater.
Primarily for high temperature, corrosive applications between -450F (-268C) and +1200F
(+649C). Above +1000F (+540C) specify carbon content of 0.04% or greater.

Corrosive or extremely high temperatures non-corrosive services between -450F (-268C) and
+1200F (+649C). Above +800F (+425C) specify carbon content of 0.04% or greater.

Corrosive or non-corrosive services to +800F (+425C).

Grade CF3
316L SS

ASTM A351

Corrosive or non-corrosive services to +800F (+425C).

Grade CF3M
Alloy-20

ASTM A351

Good resistance to hot sulfuric acid to +800F (+425C).

Grade CN7M
Monel

ASTM 743
Grade M3-35-1

Hastelloy B

ASTM A743
Grade N-12M

Hastelloy C

ASTM A743
Grade CW-12M

Inconel

ASTM A743
Grade CY-40

Bronze

ASTM B62

Weldable grade. Good resistance to corrosion by all common organic acids and salt water. Also
highly resistant to most alkaline solutions to +750F (+400C).

Is well suited for handling hydrofluoric acid at all concentrations and temperatures. Good
resistance to sulphuric and phosphoric acids to +1200F (+649C).

Good resistance to span oxidation conditions. Good properties at high temperatures. Good
resistance to sulphuric and phosphoric acids to +1200F (+649C).

Very good for high temperature service. Good resistance to spanly corrosive media and
atmosphere to +800F (+425C).
Water, oil or gas: up to 400F. Excellent for brine and seawater service.

DisadvantagesofCasting:
ThoughcastingischeapestforMASSProduction,itbecomesnon
economicalincaseofJOBproduction.
Sandcastingleavesroughsurfacewhichneedsmachininginmostofcases.
Itaddsupthecostinproduction.
Insandcasting,poordimensionalaccuracyisachieved.
Castproductsaresuperiorforcompressiveloadsbuttheyareverypoorin
tensileorshockloads.(Theyarebrittle).

Casting defects
CastingdefectsmaybedefinedThosecharacteristicsthat
createadeficiencyorimperfectiontoqualityspecifications
imposedbydesignandservicerequirements.
Reducestotaloutput,increasesthecostofproduction.
Eveninmodernfoundriestherejectionrateashighupto20%
ofthenumberofcastingproduced.
Surfacedefects:Maybevisibleonsurface,includingincorrectshape&size,
flashes,poorsurfacefinish.
Internaldefects:Thesearepresentininteriorofcast.Canberevealed
throughNDTtechniques.
IncorrectchemicalcompositionFormationofundesirablemicrostructure.
UnsatisfactorymechanicalpropertiesTheseareduetolowquality,poor
percentofusage.

CASTINGDEFECTS,FACTORSRESPONSIBLEFORTHEMAND
REMEDIES

SWELL
FIN
GasHOLES
SHRINKAGECAVITY
HOTTEAR
MISRUNANDCOLDSHUT

SWELL

Swell - enlargement of the mold cavity by metal pressures, results

localized or overall enlargement of castings
Causes
Insufficient ramming of the sand.
Rapid pouring of molten metal.
Also due to insufficient weighting of mold.
Remedies
Avoid rapid pouring.
provide sufficient ram on sands.
proper weighting of molds.

FIN
A thin projection of metal not a part of cast.
Usually occur at the parting of mold or core sections.
Causes
Incorrect assembly of cores and molds,
Improper clamping.
Improper sealing.
Remedy
Reduces by proper clamping of cores and mold.

GasHoles
Clean, smooth walled rounded holes of varying size from pin heads to
full section thickness, often exposed during machining.
Causes
Low pouring temperature.
Gases blowing from the mould.
Excessive turbulence during pouring.
Moisture condensed on densors and chills.
Remedies
Usecorrectpouringtemperatureandcheckwithpyrometer.
Increase permeability of sand and check grinding.
Warm densors and chills.
Modify gating to reduce turbulence, use sivex filter.

SHRINKAGECAVITY
Itisavoidordepressioninthecastingcausedmainlybyuncontrolled
solidification.
Causes:
1. Pouringtemperatureistoohighcausingliquidshrinkage.
2. Failuretosupplyliquidfeedmetal.
3. Prematuresolidification.
Remedies:
Applyprinciplesofcasting,reducethepouringtemperatureandprovide
adequaterisers,feeders,whichsupplythemoltenmetaltocompensatethe
shrinkage.

HOTTEAR
Oneofthemaindefectsishottearingorhotcracking,orhotshortness.Irrespective
ofthename,thisphenomenonrepresentstheformationofanirreversiblefailure
(crack)inthestillsemisolidcasting.
Cause:
Theinadequatecompensationofsolidificationshrinkagebymeltflowinthe
presenceofthermalstresses.
Remedy
Avoidexcessiveramming.
Controlledrammingshouldbedone.

MISRUN&COLDSHUT
Castingsnotfullyformheavinglinesorseamofdiscontinuityorholeswith
roundededgesthroughcastingwalls.
Causes:
Incompletefusionwheretwostreamsofmetalmeat.
Metalfreezesbeforemoldisfilled.
Dietoocold.
Remedies:
Increasepouringtemperature.
Increasedietemperatureorimproveventing.
Increasepermeabilityofsand.

InspectionMethods:
Foundryinspectionproceduresinclude;
a.VisualInspectiontodetectobviousdefects,suchasMisruns,cold
shutandseveresurfaceflaws;
b.Dimensionalmeasurementstoensurethattoleranceshavebeen
met;
c.Metallurgical,chemical,physicalandothertestsconcernedwith
theinherentqualityofthecastmetal.Testsincategory3include
1)Pressuretestingtolocateleaksinthecasting
2)Radiographicmethods,magneticparticletests,theuseof
fluorescentpenetrantsandsupersonictestingtodetecteithersurfaceorinternal
defectsinthecasting;
3)Mechanicaltestingtodeterminepropertiessuchastensile
strengthandhardness.Ifdefectsarediscoveredbutarenottooserious,itisoften
possibletosavethecastingbywelding,grindingorothersalvagemethodsto
whichthecustomerhasagreed.

CastingCostEstimation

 FINALLY THATS ALL !!!!!!