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Casting Defect Analysis Report

The report details a casting defect characterized by tearing near a central hole, attributed to issues during the metal pouring process. Possible causes include improper pouring temperature, turbulent flow, and inadequate mold venting. A corrective action plan is proposed, focusing on optimizing pouring conditions, improving mold design, and minimizing contamination.

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Ketul Shah
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54 views2 pages

Casting Defect Analysis Report

The report details a casting defect characterized by tearing near a central hole, attributed to issues during the metal pouring process. Possible causes include improper pouring temperature, turbulent flow, and inadequate mold venting. A corrective action plan is proposed, focusing on optimizing pouring conditions, improving mold design, and minimizing contamination.

Uploaded by

Ketul Shah
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Casting Defect Analysis & Corrective Action Report

1. Problem Description

A defect was observed on a metal casting near the central hole. The region shows signs of tearing, which

initially appeared like a punching defect but upon closer inspection is likely caused by issues during the metal

pouring process in casting.

2. Observed Defect Characteristics

- Tearing or rupture around the hole

- Surface roughness and discoloration

- Possible internal porosity or shrinkage

3. Possible Causes

- Improper pouring temperature

- Turbulent metal flow

- Inadequate venting

- Contaminated or moist molds

- Poor gating or mold design

4. Corrective Action Plan

- Optimize pouring temperature based on alloy specifications

- Improve mold venting to allow proper gas escape

- Ensure mold dryness and cleanliness

- Redesign gating and riser system to enhance flow

- Use degassing agents and filtering techniques to minimize porosity

5. Defect Cause & Corrective Action Chart

Defect Type Possible Cause Corrective Action

Shrinkage Cavity Inadequate feeding during solidification Redesign risers; improve feeder head placement a

Gas Porosity / Blowhole Turbulent pouring, trapped gases, or moist mold


Control pouring speed; improve mold venting; ensu
Casting Defect Analysis & Corrective Action Report

Cold Shut / Misrun Low pouring temperature; slow flow Increase metal temperature; improve gating system

Inclusion Defects Foreign materials (slag, sand) in metal Clean ladles; filter molten metal; use flux

Cracks / Hot Tears Rapid cooling; improper mold design Optimize cooling rate; modify mold design to reduc

Incomplete Filling Poor gating design or low metal flow Enlarge gates/runners; maintain correct metal head

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