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Green Sand Casting Defect!
Foundrymen often are stumped by the origin of casting
defects. To aid in the analysis, this article explores common
green sand defects, their causes and possible remedies.
Ian Kay and Mark Nagel, Cast Metals Institute (CMI), Des Plaines, Illinois
Alfred T. Spada, Executive Editor
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AFS Library Copy: 20020203A.pdf, Page 1 of 4 Pages, Provided to User for Internal Use and Not Public Redistribution or Resale.
Copyright 2002 American Foundry Society.
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Copyright 2002 American Foundry Society.
use a mold coating as a prethe gases released from the deventative barrier against the
composing mold and core mametal at the mold interface;
terials to follow, rather than
add a finer sand to the mix if
through the metal. Venting also
the GFN is too coarse for bethelps in situations where low
ter mold compaction;
permeability is a problem.
check metal chemistry and
Another factor related to venttemperature (especially in
ing is core print size. Smaller
iron) to ensure proper fluidity;
prints make the flow of gas
improve the mold filling with
through the prints difficult. Ofbetter gating to reduce velociten, venting of the cores through
Fig. 6. PINHOLESA gas defect, it is denoted by numerous
ties and avoid hot spots;
the print area can reduce or
small holes in the casting due to entrapped, soluble or
increase carbon additives
eliminate gas defects in castings.
reactive gas.
(seacoal) in the mold to creAnother aid can be core washes
ate the reducing atmosphere in
or coatings, which will help reduce
the mold that produces better surentrapped gas defects by sealing
face finish.
the surface of the core, forcing the
gas out through the core prints.
Gas Defects
Although venting molds and cores
Gas Defects are divided into two
can help reduce gas defects, a vent
major categoriesblows (Fig. 5),
only is effective while it is open. Vents
which are large voids in the casting,
on top of the casting cavity will allow
and pinholes (Fig. 6), which are
gases to escape prior to the complete
numerous small holes. For the most
filling of the cavity or possibly while
part, these gases can occur in castthe metal is in the molten state. Once
ings due to two mechanismsenthe vent fills with metal, it quickly
trapped gas and soluble gas.
freezes off. At that point, no further
Entrapped GasEntrapped gas is Fig. 7. STICKERSThis defect results from the mold- removal of gas from the mold cavity
ing sand sticking to the pattern as it is drawn from
derived from the thermal decompo- the mold.
can occur. This idea also applies to
sition of mold and core materials or
core print vents if the metal leaks
air and mold gas washed into the
into the print area. Sloppy fitting cores
casting from the gating system. Entrapped gases are free gases
often show gas related defects.
Soluble GasThis refers to gases that dissolve in molten
that float to the top of the molten metal as the casting solidifies.
metal. Aluminum alloys will dissolve hydrogen. Iron alloys will
Entrapped gas from core or mold binders occurs when
dissolve hydrogen and nitrogen. Copper base alloys will disthese organic materials degrade as they are exposed to the
solve hydrogen and oxygen. Steel alloys will dissolve hydrogen,
heat of the molten metal. The greater the amount of resin
nitrogen and oxygen. The problem is that molten metal can
used to manufacture the cores and molds, the greater the
hold a greater amount of gas in solution than solid metal can.
amount of gas to be generated. Entrapped gas from the gas
This means that large amounts of gas that may dissolve in
design occurs at the sprue or as metal flows through the
the liquid metal during melting, pouring and mold filling will
downsprue, runners and ingates. During pouring, care must
be expelled from the metal as it solidifies. During solidificabe taken to ensure that the sprue remains full and gas isnt
tion, the dissolved gases will precipitate into tiny bubbles of
pulled down with the metal. Also, if the poured metal undergas, forming pinholes in the casting.
goes excessive turbulence while flowing through the gating
Pinholes also may result from soluble gases near the
system, air and gas can become entrained and flushed into
casting surface. High sand moisture and combustible levels
the casting cavity.
in the mold may lead to the formation of these defects. As
If an entrapped gas bubble floats to the top of the mold
with entrapped gas, increasing sand permeability and mold
cavity, the gas should permeate into the molding sand before
and core venting can reduce these problems.
the metal can solidify around it. If the permeability is not
Remedies for gas related defects include:
sufficient, the gas may not have enough time to leave the
reduce the combustible level of the sand because commetal before solidification takes place.
bustibles create gas during pouring;
The force that pushes gas into the sand is the metal head
reduce the moisture content of the sand because moisture
pressure. If enough head pressure is not above the top of the
means more steam (gas);
casting, then the gas may not be expelled quick enough.
increase the sand permeability to allow the gases to esThe pouring temperature also is critical in ensuring trapped
cape through the mold;
gases are out of the casting. If a mold is poured too cold, the
with entrapped gases, increase the metal pouring temperametal quickly forms a solid skin. If the gas reaches the top of the
ture to increase metal fluid life, which provides entrapped
casting cavity after a skin has formed, the gas cannot permeate
gases more time to escape the mold and/or metal;
the solid metal skin and enter the sand.
with soluble gases, reduce the pouring temperature to
Another consideration with entrapped gas is mold/core
reduce the chance for gases to be dissolved in the metal;
venting. Gas is lazy. It simply follows the easiest route away
vent molds and cores to provide the gases a highway to
from where it is formed (path of least resistance). If gas is
escape through;
formed in the molding sand and the easiest way out is through
fill the mold quickly but quietly to avoid turbulence and
the metal, than that is where it will go. If gas can go through the
entrained oxides. Also, the quicker a mold fills, the less time
metal easier than through a core, then it will follow that route.
allowed for gases to form;
The venting of molds and cores provides an open path for
modern casting / September 2001
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AFS Library Copy: 20020203A.pdf, Page 3 of 4 Pages, Provided to User for Internal Use and Not Public Redistribution or Resale.
Copyright 2002 American Foundry Society.
32
AFS Library Copy: 20020203A.pdf, Page 4 of 4 Pages, Provided to User for Internal Use and Not Public Redistribution or Resale.
Copyright 2002 American Foundry Society.