Term 2: Fifth Year
Department of Metallurgical Engineering
School of Mines
University of Zambia
FOUNDRY TECHNOLOGY
(MET 5349)
• Additional steps after casting
• Casting defects and Inspection
Dr. L. Subashini
CASTING DEFECTS
Misrun Cold shut
Cold shots Shrinkage
SAND CASTING DEFECTS
Sand blow Pinholes
Penetration Moldshift/ Mismatch
Casting inspection
• Casting inspection refers to the systematic examination and evaluation
of cast products to ensure they meet the required quality, dimensional
accuracy, and material standards.
• The goal is to detect and correct defects before the component enters
service or further processing.
Importance of Casting Inspection
•Ensures reliability and safety of cast components
•Prevents failure during service
•Reduces economic losses due to rework or rejection
•Ensures compliance with technical standards and customer requirements
Classification of Inspection Methods
Casting inspection methods may be broadly categorized into visual,
dimensional, non-destructive, and destructive techniques.
Visual Inspection
Purpose: Preliminary assessment of surface quality and workmanship
Detectable Defects: Surface cracks, cold shuts, blowholes, misruns and
shrinkage porosity
Instrumentation: Visual aids such as magnifying glasses, borescopes, and high-
resolution imaging systems
Dimensional Inspection
Purpose: Verification of cast dimensions against engineering drawings and
tolerances
Equipment: Vernier calipers, micrometers, height gauges, and coordinate
measuring machines (CMMs)
Application: Critical where precision and fit are essential, such as in aerospace
and automotive components
Non-destructive testing (NDT)/ Non-destructive evaluation (NDE)
NDE is a class of physical and chemical tests that enable the detection of
internal or surface discontinuities without compromising the integrity of the
casting.
NDT Methods
• Visual Inspection
• Liquid penetrant testing
• Magnetic Particle Inspection
• X-Ray Radiography
• Ultrasonic Testing
Magnetic Particle Inspection
Magnetic Particle Inspection
Applicable Materials:
Ferromagnetic castings such as
carbon and low-alloy steels
Working Principle: Magnetic fields
cause leakage flux at defect sites,
attracting magnetic particles
Detects: Surface and near-surface
flaws
Dye/Liquid penetrant testing (LPT/DPT)
Applicable Materials: Non-porous, non-
ferromagnetic metals
Process: Surface is cleaned, penetrant
applied, excess removed, and developer
used to reveal discontinuities
Detects: Surface cracks and porosity
Radiography Testing (X-Rays or Gamma Rays)
• Utilizes X-rays or gamma rays to penetrate the casting; defects are
revealed on radiographic film or digital detector arrays
• Capable of detecting internal defects such as shrinkage cavities,
inclusions, and gas porosity
• Limitations: High cost, safety considerations, and limited effectiveness
in detecting planar defects
Ultrasonic Testing
• Principle: High-frequency sound
waves are transmitted through
the material; reflections from
discontinuities are analyzed
• High sensitivity, real-time
evaluation, suitable for thick and
large castings
Destructive Testing (DT)
Destructive testing involves physically altering or removing material from the
casting to evaluate mechanical properties and internal structure.
Sectioning and Macro-Examination
Cut sections of castings are examined for internal voids, inclusions, or improper
fusion
Mechanical Testing
- Tensile Testing: Determines yield strength, ultimate tensile strength, and
ductility
- Hardness Testing: Common methods include Brinell, Rockwell, and Vickers
- Impact Testing: Charpy and Izod tests assess toughness, particularly for low-
temperature applications
Specialized Inspection Techniques
Pressure (Leak) Testing
• Application: Used in pressure-retaining castings such as valves, pumps,
and engine blocks
• Method: Subjecting the casting to fluid pressure and monitoring for leaks
or pressure drops
Metallographic Examination
• Involves mounting, polishing, and etching a sample to study the
microstructure using optical or electron microscopy
• Reveals grain structure, phase distribution, and presence of non-metallic
inclusions
Standards and Quality Criteria
Casting inspection adheres to internationally recognized standards that define
acceptable quality levels, defect classifications, and inspection procedures.
Examples of Relevant Standards
- ASTM A802 – Visual inspection of steel castings
- ASTM E165 – Dye penetrant testing
- ISO 8062 – Geometrical tolerancing and dimensional requirements for castings
- EN 1371 – Radiographic examination of castings
Summary of Typical Casting Defects and Inspection Methods
Defect Type Detection Method
Surface cracks Visual, DPT, MPT
Gas porosity Visual, RT
Shrinkage cavities RT, UT
Cold shuts Visual, DPT
Inclusions RT, Metallographic examination
Dimensional deviations CMM, micrometry, templates
Assignment 3
1. Read about additional steps after casting
2. Write up on Casting Defects: Causes and Remedies
