C A S T I N G D E F E C T S

CASTING DEFECTS

C A S T I N G D E F E C T S

Basic categories of casting defects:

Metallic projections Cavities Discontinuities Defective surfaces Incomplete casting Incorrect dimension Inclusions or structural anomalies

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Metallic projections

C A S T I N G D E F E C T S

Metallic projections in the form of fins or flash Metallic projections in the form of fins (or flash) without change in principal casting dimensions Joint flash or fins Thin fins (or flash) at the parting line or at core prints

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Veining or finning Projections in the form of veins on the casting surface

Heat-checked die Network of projections on the surface of die castings

 Fillet scab

C A S T I N G D E F E C T S

Thin projection parallel to a casting surface, in re-entrant angles

Fillet vein Thin metallic projection located at a re-entrant angle and dividing the angle in two parts

 Cracked or broken mold

C A S T I N G D E F E C T S

Formation of fins in planes related to direction of mold assembly (precision

casting with waste pattern); principal casting dimensions change

Erosion, cut, or wash

Excess metal in the vicinity of the gate or beneath the sprue

 Crush

C A S T I N G D E F E C T S

Metal projections in the form of elongated areas in the direction of mold assembly

Mold drop or sticker Projections with rough surfaces on the cope surface of the casting

 Raised core or mold element cutoff

C A S T I N G D E F E C T S

Projections with rough surfaces on the drag surface of the casting (massive
projections)

Raised sand Projections with rough surfaces on the drag surface of the casting (in dispersed areas)

 Mold drop

C A S T I N G D E F E C T S

Projections with rough surfaces on other parts of the casting

Corner scab Projections with rough surfaces over extensive areas of the casting

Broken or crushed core Projections with rough surfaces in an area formed by a core

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Cavities

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Blowholes, pinholes Internal, rounded cavities, usually smooth-walled, of varied size, isolated or grouped irregularly in all areas of the casting

Blowholes, adjacent to inserts, chills, chaplets, etc.

As above, but limited to the vicinity of metallic pieces placed in the mold (chills, inserts, chaplets, etc.)

 Slag blowholes

Surface pinholes

C A S T I N G D E F E C T S

Surface or subsurface blowholes

Dispersed shrinkage

Corner blowholes, draws

Open or external shrinkage

 Corner or fillet shrinkage

C A S T I N G D E F E C T S

Macro- or microshrinkage, shrinkage porosity, leakers Core shrinkage

Internal or blind shrinkage

Centerline or axial shrinkage

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Discontinuities

 Breakage (cold)

C A S T I N G D E F E C T S

Normal fracture appearance, sometimes with adjacent indentation marks

Hot cracking Fracture surface oxidized completely around edges

Cold tearing Discontinuities with squared edges in areas susceptible to tensile stresses during cooling; surface not oxidized

 Hot tearing

C A S T I N G D E F E C T S

Irregularly shaped discontinuities in areas susceptible to tension; oxidized fracture

surface showing dendritic pattern

Quench cracking Rupture after complete solidification, either during cooling or heat treatment

Cold shut or cold lap Complete or partial separation of casting wall, often in a vertical plane

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Interrupted pour Separation of the casting in a horizontal plane

Chaplet or insert cold shut, unfused chaplet

Local discontinuity in vicinity of metallic insert

Conchoidal or "rock candy" fracture Separation along grain boundaries of primary crystallization

Intergranular corrosion Network of cracks over entire cross section

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Defective Surface

 Surface folds, gas runs

C A S T I N G D E F E C T S

Fold markings over rather large areas of the casting

Cope defect, elephant skin, laps Surface shows a network of jagged folds or wrinkles (ductile iron)

Seams or scars Wavy fold markings without discontinuities; edges of folds at same level, casting surface is smooth

Flow marks Casting surface markings showing direction of liquid metal flow (light alloys)

 Rough casting surface

C A S T I N G D E F E C T S

Depth of surface roughness is approximately that of the dimensions of the sand grains

Severe roughness, high pressure molding defect Depth of surface roughness is greater than that of the sand grain dimensions

Buckle Grooves of various lengths, often branched, with smooth bottoms and edges

 Rat tail

C A S T I N G D E F E C T S

Grooves up to 5.1 mm (0.2 in.) in depth, one edge forming a fold which more or
less completely covers the groove

Flow marks, crow's feet Irregularly distributed depressions of various dimensions extending over the casting surface, usually along the path of metal flow (cast steel)

Orange peel, metal mold reaction, alligator skin Casting surface entirely pitted or pock-marked

 Soldering, die erosion

C A S T I N G D E F E C T S

Grooves and roughness in the vicinity of re-entrant angles on die castings

Sink marks, draw or suck-in Casting surface depressions in the vicinity of a hot spot

Slag inclusions
Small, superficial cavities in the form of droplets of shallow spots, generally graygreen in color

 Push-up, clamp-off

C A S T I N G D E F E C T S

Deep indentation, often over large area of drag half of casting

Burn on Sand layer strongly adhering to the casting surface

Burn in Very adherent layer of partially fused sand

Metal penetration Conglomeration of strongly adhering sand and metal at the hottest points

of the casting (re-entrant angles and cores)

Dip coat spall, scab Fragment of mold material embedded in casting surface

 Scabs, expansion scabs

C A S T I N G D E F E C T S

Plate-like metallic projections with rough surfaces parallel to casting surface;

removable by burr or chisel

Cope spall, boil scab, erosion scab As above, but impossible to eliminate except by machining or grinding

Blacking scab, wash scab Flat, metallic projections on the casting where mold or core washes or dressings are used

 Oxide scale

C A S T I N G D E F E C T S

Adherence of oxide after annealing

Adherent packing material Adherence of ore after malleablizing (white heart malleable

Scaling Scaling after anneal

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Incomplete Casting

 Misrun

C A S T I N G D E F E C T S

Casting is essentially complete except for more or less rounded edges and
corners

Defective coating (teardropping) or poor mold repair Deformed edges or contours due to poor mold repair or careless application of wash coatings

Poured short Casting incomplete due to insufficient metal poured

C A S T I N G D E F E C T S

Runout Casting incomplete due to loss of metal from mold after pouring

Fusion or melting during heat treatment Casting partially melted or seriously deformed during annealing

Fractured casting Casting broken, large piece missing; fractured surface not oxidized

Broken casting (at gate, riser, or vent) Fracture dimensions correspond to those of gates, vents, etc.

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Incorrect Dimensions or Shape

 Improper shrinkage allowance

C A S T I N G D E F E C T S

All casting dimensions incorrect in the same proportions

Hindered contraction

Distance too great between extended projections

Irregular contraction

Certain dimensions inexact

Excess rapping of pattern Dimensions too great in the direction of rapping of pattern

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Soft or insufficient ramming, mold-wall movement Excessive metal thickness at irregular locations on casting exterior(a) Distorted casting Thin casting walls over general area, especially on horizontal surfaces(b) Pattern error Casting does not conform to the drawing shape in some or many respects; same is true of pattern (c) Pattern mounting error Casting shape is different from drawing in a particular area; pattern is correct(d)

 Shift

C A S T I N G D E F E C T S

Casting appears to have been subjected to a shearling action in the plane of the
parting line

Shifted core Variation in shape of an internal casting cavity along the parting line of the core

Ramoff, ramaway Irregular projections on vertical surfaces, generally on one side only in the vicinity of the parting line

 Deformed pattern

C A S T I N G D E F E C T S

Deformation with respect to drawing proportional for casting, mold, and pattern(a)
Deformed mold, mold creep, springback Deformation with respect to drawing proportional for casting and mold; pattern conforms to drawing (b) Casting distortion (d) Casting deformed with respect to drawing; pattern and mold conform to drawing(c) Warped casting Casting deformed with respect to drawing after storage, annealing, machining(d)

(a)

(b)

(c)

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Inclusions or Structural Anomalies

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Metallic inclusions (a) Cold shot (b) (a) Internal sweating, phosphide sweat (c)

Slag, dross or flux inclusions, ceroxides (d)

Slag blowhole defect (e)

(b)

(c)

(d)

(e)

 Sand inclusions (a)

C A S T I N G D E F E C T S

Blacking or refractory coating inclusions (b) Black spots (c) Oxide inclusion or skins, seams (d) Lustrous carbon films, or kish tracks (e) Hard spots (f) (b) (c) (a)

(d)

(e)

(f)

Summary
C A S T I N G D E F E C T S

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