ISSN : 2456-3463

International Journal of Innovations in Engineering and Science, Vol. 1, No.3, 2016

Root Cause Analysis of Defects in Duplex Mould

Casting

A.G.Thakare1, Dr.D.J.Tidke2
1
Research Scholar, 2Ex. Professor
G.H.Raisoni College of Engineering, Nagpur, India

Abstract – Casting defects are usually easy to manufactured right from very small to large with
characterize but to eradicate them can be a difficult task. complex designs. Casting process is also known as
Defects are the result of combination of different factors process of uncertainty. Defects in casting occur even in a
whose identification is often a very difficult task. Casting completely controlled process which challenges
is a complex process which involves complex explanation about the cause of casting defects. Foundry
interactions among various parameters and operations industry suffers from poor quality and productivity due
related to metal composition, methods process, melting, to large process parameters, combined with lower
pouring, machining. Presence of these defects exposes penetration of manufacturing automation and shortage of
foundries to contribute over 70% of total quality costs. skilled workers compared to other industries. It is very
Foundries try to reduce rejections by experimenting with difficult to find the cause of defects because casting
process parameters, when this is ineffective they try to process itself is very complex due to involvement of
modify methods design, when this fails then they try to various disciplines of science and engineering. Often
modify tooling design. So approach of foundries is cause of defects is combination of several factors rather
completely on trial and error basis. Foundries must try than a single one. When these various factors are
to reduce rejections by systematically finding the combined, the root cause analysis can actually become a
reasons responsible for occurrence of defects and mystery. Defect symptoms should be correctly identified
analyze them. In this paper analysis of defects in Duplex prior to assigning cause to the problem. Defects should
Mould Casting has been carried out. All the major be correctly identified for right remedial measures
defects in Duplex Mould Casting along with causes and otherwise false remedies not only fail to solve the
remedies have been discussed. This will be helpful to problem but they can confuse the issues and make it
quality control engineers for root cause analysis and more difficult to cure the defect which might result into
finding correct remedial action so as to avoid the defects new defects [1].This shows how complex and how
before they result in rejection of Duplex mould casting, difficult it is to carry out the root cause analysis of
which is very costly affair. casting defects in Duplex Mould Casting.

Keywords- Casting defects, Duplex Mould Casting DUPLEX MOULD CASTING

INTRODUCTION In this paper different defects observed in Duplex Mould

Casting are analyzed. Pencil ingots are being made with
the help of these cast iron ingot moulds. For
Metal casting is one of the direct methods of manufacturing these moulds high quality metals are used
manufacturing desired geometry of component. Casting which are very costly. Weight of each duplex mould
is manufactured by creating a cavity inside sand mould varies from a minimum of 442 kilograms to maximum
and then pouring the molten metal directly into mould 667 kilograms. This study has been carried out at one of
.It’s a versatile process which is capable of being used in the leading casting manufacturer in Central Maharashtra
mass production. All sizes of components can be which has manufacturing capacity of 30,000 metric ton
per year and range of products. It manufactures around
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International Journal of Innovations in Engineering and Science, Vol. 1, No.3, 2016

200 ton/month of Duplex Mould .It is also observed that be disengaged with such violence as to break up the sand
rate of rejection of these casting is very high, maximum which is then washed away and the resulting cavity filled
rejection of around 12% in rainy season and minimum with metal. Scab is a projection on casting which occurs
rejection of around 4% in summer. Owing to such heavy when a portion of mould face or core lifts and the metal
rejection capital losses are also very high. Study has flows beneath a thin layer. They are rough irregular
been carried out to find the exact causes of rejection on projections on the surface containing embedded sand.
the basis of data collected for past three years. After
analysis it is observed that few defects were repetitive Causes
resulting in defective castings. In this paper critical
1. It may be caused due to Hard or uneven ramming.
defects resulting in rejection of duplex mould casting,
causes of defects and remedies to minimize these defects
2. If the Mould poured too slowly then it might result in
are discussed, which will be immensely beneficial for
scab.
cast iron ingot mould manufacturers.
3. Another reason scab may be because Sand grain is too
uniform.
4. It may also be the result of excessive moisture or
volatile content.
5. Low permeability of sand also results in scab on
casting surface.
6. Sand erosion due to weak bond or facing sand also
leads to this type of defect.
7. Sand erosion due to prolonged metal impingement
also leads to scab.

Remedy

1. To control scab avoid hard rammed areas especially

close to pattern.
Fig. 1 : Duplex Mould
2. Another way of controlling scab is Increase the ingate
DEFECTS IN DUPLEX MOULD area and/or number of gates.

Bar Chart shows analysis of defects observed during 3. Change sand grading or make an addition of anti-
span of one year .It is observed that these defects were scabbing additive
main contributors leading to rejection of Duplex Mould
Casting. 2. Shrinkage
These are rough cavities entering
casting on heavy sections or at junction of change of
sections. These are saucer shaped depressions on
exterior of heavy sections usually with rough edges.
These are dark spongy areas seen in fracture. When feed
metal is not available to compensate for shrinkage as the
metal solidifies, shrinkage defect occurs. These are
classified into two categories: open shrinkage defects
and closed shrinkage defects. In open shrinkage defects
as the shrinkage cavity forms air compensates because
Fig. 2:Critical defects leading to rejection
they are open to the atmosphere. Closed shrinkage
1. Scab defects are formed within the casting. They are also
known as shrinkage porosity [2].
This type of defect occurs when portion of face of a
mould breaks down and the recess thus made is filled by
metal. When the metal is poured into the cavity, gas may

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International Journal of Innovations in Engineering and Science, Vol. 1, No.3, 2016

solidification time. During the casting of iron-carbon

alloys, oxide inclusions and slag with a high oxidation
potential (e.g. high manganese and ferrous oxide
contents) react with the graphite, resulting in the
formation of CO blowholes. Other gases from the melt
may migrate into the CO cavities.

When melting metal in the presence of oxygen,

slag and oxides occur .These frequently react with the
furnace or ladle lining. Oxides generated also react with
the ash residues from the pit coal coke, when melting
grey cast iron in cupola which results in silicate slag.
The metal flowing into the mould also forms oxides,
which may react with the moulding sand and its
Fig. 3: Shrinkage
components. Highly oxidizing additions (alloy
Causes components, inoculants) may be responsible for the
formation of oxides and sand.
1. One of the major reason contributing to shrinkage
defects is Incorrect gating and feeding.

2. Another reason resulting into shrinkage defects is

unsuitable composition in relation to suitable
thickness of casting.

3. Poor design of casting might also result in shrinkage

defects.

Remedy

1. To avoid shrinkage defects always use risers to feed

heavy sections and ensure that they are filled with hot
metal. If open risers are used always use feeding
Fig. 4 : Slag
aids, if using blind risers use blind sleeves with
Williams cores where a heavy section or boss cannot Causes
fed directly with riser.
1. One of the major causes of slag is dirty metal and
2. Another way of controlling shrinkage defects is
ladle linings, poor skimming practice.
adjust silicon and /or carbon content.
2. Slag is also the result of Incorrect gating, causing
3. If possible and not controlled through other means
turbulence.
consider modification of design.
3. Excess of sulphur with high manganese and low
3. Slag pouring temperature also results into slag.
4. Another reason resulting in slag is because of
This is pitted surface or inclusions found on machining. Manganese and silicon contents approaching same
Cavities are saucer shaped and smooth. Slag may be level.
seen before cleaning the casting. Slag is an Irregular-
shape, non-metallic inclusions, frequently on upper Remedy
casting surfaces, which may occur in association with
gas blowholes. It is found at the microstructure grain 1. Remove all slag from metal before pouring. Control
boundaries as well as on the surface of the casting. It slag with a slag coagulant. Keep ladle linings free
appears in association with gas cavities. Highly viscous from buildup.
slugs appear in the microstructure of casting. Low 2. To avoid slag incorporate skim gates or strainer cores
viscosity slugs rise more quickly to the surface of the in runner systems. Keep runner bush full while
casting. Low viscosity slag may also be included in the pouring. Use runner extensions.
casting in event of severe turbulence and a short 3. Restrict sulphur pick-up and avoid pouring with dull
iron to avoid slag.
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International Journal of Innovations in Engineering and Science, Vol. 1, No.3, 2016

4. Avoid large excess of manganese in order to avoid 4. Pack casting with wood or old tyres in tumbler. Take
slag. care in breaking off risers. See that risers are
provided with correctly designed necks.
4. Crack
5. Blow Holes
Crack is formed at low temperatures in the spot where
the alloy is subjected to elastic deformation. It is a When hot metal is poured inside the sand mold, sand
straight or slightly curved and zigzagging crevice in and sand contents gets heated and large amount of gases
casting wall. Cracks are formed after the casting is are produced inside the casting. This is one of the major
cooled down in a mould or while knocked out or due to reasons of rejection of castings. This is caused due to
premature removal from mould. Rarely it is observed evolution of gases which results into holes (gas holes) on
that cracks also occur during later heat treatment. casting surface. Gas holes are pinholes and blowholes.
Depending on the temperature and on the process stage These are smooth walled cavities, essentially spherical,
at which the crack is formed i.e. when cooling down in a often not contacting the external casting surface. The
mould, during de-gating and infusions with oxygen, or largest cavities are often isolated. In some cases these
while heat treated. Surface of the crack is usually grainy are scattered over the casting surface. The interior walls
and clean, sometimes with colored swelling, or distinct of blowholes can be shiny, more or less oxidized or in
signs of oxidation [3].When broken, discoloration shows case of cast iron can be covered with a thin layer of
that crack was produced while casting was hot. No graphite [4].
discoloration shows cold crack.
Blowholes are usually revealed by machining or
by heavy shot blasting. This defect may take form of
well defined bubble shaped cavities beneath the surface
of casting. Major reason for blow holes is entrapment of
more than one sort of gas during the course of mould
filling and solidification. For correct diagnosis of these
defects origin of and reactions producing these gases
should be known.

Fig. 5 : Crack

Causes

1. One of the major reasons for crack is high dry strength

of sand.

2. Crack also occurs when the cores are too hard.

3. Crack may also happen because of the casting strains.

4. Mechanical reasons can also result in cracks on

casting.

Remedy

1. To avoid cracks on casting ram softer to allow casting

to contract. Fig . 6 : Blow Holes

2. Reduce binder content of cores to avoid cracks on Causes

casting.
1. One of the major reasons resulting in blow holes is
3. Another method of avoiding the occurrence of cracks because of insufficient permeability of moulding or
on casting is gate evenly. Cracks can also be reduced core sand.
by modifying pattern design.
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2. Hard ramming also results in blow holes on casting. 6. Sand Inclusion

3. High moisture content is another reason resulting in Areas of sand are torn away by metal stream and then
blow holes in casting. float to the surface of casting because they cannot be
wetted by the molten metal. In combination with metal
4. Blow holes also occur on casting surface because of oxides and slags they can also be trapped under the
rusty or damp chills and chaplets. casting surface and only visible during machining.

5. Blowing from core jointing material results in blow Sand inclusions occur at widely varying
holes on casting surface. positions and are therefore very difficult to attribute to a
local cause and to diagnose. It is one of the most
6. Insufficient head pressure might also lead to blow
important causes of casting rejection. Sand inclusions
holes on casting surface.
appear along with CO blowholes and slag particles [2].
7. Incomplete baking of cores etc. also results in blow
holes.

8. Damp pouring ladles is another reason which results

in blow holes.

9. Too low pouring temperature might also result in

blow holes on casting surface.

10. Lack of venting or blocked vents is another major

reason which results in blow holes.

11. Incompletely dried dressings might also result in

blow holes.
Fig. 7 : Sand Inclusion
Remedy
Causes
1. Increase permeability by use of vent wire or open
sand with additions of a coarser silica sand. 1. Loose sand that is emulsified during pouring into the
mould results in sand inclusion.
2. Avoid excess ramming in order to avoid blow holes.
2. Erosion of packed or loosely bonded sand under
3. Reduce moisture to minimum, consistent with
areas of turbulent stream contact with the mould.
workability.
4. Ensure chaplets are dry and coat chills with suitable 3. Corrosion of mould due to the combination of
dressing before use. turbulent stream and reoxidation also results in this
type of defect.
5. Use core jointing pastes of proved reliability to avoid
blow holes. 4. Corrosion of the mould due to high pouring
temperatures and high mould preheats also results in
6. Blow holes can also be avoided by ensuring adequate sand inclusion on casting surface.
pouring head.
Remedy
7. Another way of reducing blow holes is to bake until 1. To avoid sand inclusion check moulds for pressure
centre is dry and hard. marks and, if necessary, inserts pressure pads.
8. Thoroughly preheating all pouring ladles is another
2. Improve pattern plates, increase pattern tapers and
way by which we can reduce blow holes.
radii to reduce sand inclusion.
9. To reduce blow holes increase pouring temperature.
3. Ensure uniform mould compaction, avoid over
10. Another effective method of controlling blow holes compacted sections to reduce sand inclusion.
is vent well and keeps metal from entering core
prints.
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4. Another way of reducing sand inclusion is to raise Causes

compatibility and thus plasticity of the sand.
1. One of the major reasons resulting in sand drop is
5. By increasing bentonite content we can reduce sand due to weak or improperly rammed sand.
inclusion. Also use bentonite with high specific
binding capacity. 2. Existence of low moisture content also results in
sand drop.
6. Reduce inert dust content. Decreasing dust content
reduces lumps in the sand and thus reduces chances 3. Another reason resulting in sand drop is due to rough
of sand inclusion in sand casting. and careless handling.

7. Avoid high pouring rates and impact of metal stream 4. Worn out patterns or patched moulds also result in
against mould walls to avoid sand inclusion in sand drop.
casting.
5. Insufficient draft on the pattern is another reason
8. Another method of controlling this defect is to resulting in this type of defect.
shorten pouring times, improve distribution of
Remedy
gates.
1. Ensure proper ramming of the moulds in order to
9. Avoid core mismatching to reduce sand inclusion in
reduce sand drop.
castings.
2. Handle moulds carefully in order to avoid sand drop.
7. Sand Drop/ Mould Crush
3. Avoid sharp corners and deep pockets in order to
This defect resembles a sticker in appearance. This avoid sand drop.
defect occurs due to the loss of a portion of sand from
4. Ensure adequate moisture content in order to avoid
the core or other overhanging section [5]. It is irregularly
sand drop.
shaped projection on the cope surface of a casting. This
defect is caused by the break-away of a part of mould 8. Mould Breaking
sand which falls into the cavity which results in dirty
casting surface either on the top or bottom surface of During the pouring process the moulds are broken and
casting depending upon the relative densities of the sand the causes can be identified as.
and the liquid. In this defect cope surface cracks and
breaks, thus the pieces of sand fall into molten metal. Causes

1. Uneven and hard ramming results in mould crush.

2. Inadequate gating and risers is another reason for

mould crush.

3. Use of sand with high moisture content and low clay

content also results in mould crush.

4. Mould crush can also be the result of inadequate

pouring rate and excessive pouring temperature.

Remedy

1. Ensure careful and soft ramming in order to avoid

mould crush.

2. Use of sand with correct moisture content and clay

content to avoid mould crush.
Fig. 8 : Sand Drop
3. Increasing the percentage of coal or cereal also
reduces chances of mould crush.
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4. Avoid the usage of very high proportion of new sand 2. Process of withdrawing the pattern from the sand also
in order to avoid mould crush. results in dimensional variation of casting.

5. Another method of avoiding mould crush is to 3. Moisture content of the sand is another major reason
maintain adequate pouring rate with correct pouring resulting in dimensional variation of casting.
temperature.
4. Temperature of molten metal also results in
9. Dimensional Variation dimensional variations of casting.

Sand casting is used to produce large parts because they 5. Speed of molten metal entering the mould cavity also
cannot be cast by any other process. Almost any metal results in dimensional variation of casting.
that is melted can be sand cast .As a result of sand
mould; sand castings have a grainy surface with large Remedy
dimensional variation. Local finish machining operations
1. To reduce dimensional variations in casting check the
are often required to obtain necessary surface finish and
pattern equipment and core boxes.
dimensional tolerances on casting.
2. Another remedial measure to control dimensional
In sand casting material of pattern can also lead
variation in casting is core print clearance.
to large dimensional variations due to thermal expansion
in situation where there are large ambient temperature 3. To control dimensional variation in casting check the
variations especially if the material of pattern has high mould making, mould box guides.
coefficient of expansion. Plastic or wood patterns are
more thermally stable but might wear faster than metal 4. Compacting the mould can be another way of
patterns. Different metals have different heat capacities reducing dimensional variation in sand casting.
which affects the amount of expansion that occurs in the
mould. Higher combined heat capacity and latent heat 10. Cold Shut
the greater the changes in size of mould.
It is a visual and structural discontinuity caused by
Non uniform solidification and variations in the separate metal flows or where two or more metal streams
subsequent thermal contraction on cooling to room have come together and fused. This usually occurs in
temperature can also be due to variation in the chemical thin flat sections of the casting[6].Cold shut is caused
composition of alloy. In cast irons a high carbon when molten metal flow comes into contact with the
equivalent combined with a soft moulding medium can cooler die surface and solidifies before complete filling
lead to an expansion of the casting with respect to the of the mould. Another flow of metal fills in the mould
original mould size. Another reason of dimensional and lies on top of the previous metal instead of remelting
variation is mould media . For example silica sand goes it which causes the crack. Cold shuts can affect
through a phase change at around 530 ̊ and an mechanical strength of the casting as cracks would
accompanying change in particle size, so during this extend when the casting is under certain loading. The
phase it is very difficult to control dimensions. The crack will act as stress point and weaken the casting.
amount of sand that will change will depend on the
amount of heat absorbed by the sand, which again is
dependent on the section thickness of casting and the
alloys being cast. Dimensional tolerances achievable in
the sand casting process have a wide range as it is very
process dependent. High tolerances are achieved mainly
by trial and error. Ability to predict changes accurately
and routinely without the expensive trial and error stage
is still the holy grail of the process community.

Causes

1. One of the reasons resulting in dimensional variation

of sand casting is due to sand packing density. Fig. 9 : Cold Shut

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Causes 1. High initial gas content results in subsurface.

2. Mould metal reaction is another reason which results
1. Lack of fluidity in molten metal results in cold shut.
in this type of defect on casting surface.
2. Faulty design of mould can also lead to cold shut in 3. Reaction of carbon and oxygen also leads to
casting. subsurface defect.

3. Faulty gating is another reason for cold shut in

casting.

4. Low metal or mould temperature can also result in

this type of defect.

5. Low shell permeability can also lead to cold shut.

6. Low metal fluidity is one of the main reasons for cold

shut.

7. Poor pouring practice is very common in casting

which results in this type of defect.

Remedy
Fig. 10 : Subsurface
1. Increase metal and mould temperature to avoid cold
shut. 4. High pouring rate is another reason which results in
2. Another way of avoiding cold shut is to increase head this type of defect.
pressure and /or rate of pour as well as avoid
5. Excessive moisture in moulds and cores can also lead
splashing.
to subsurface defect.
3. Improve gating to enhance mould fill which also
controls cold shut. 6. Entrainment of air due to turbulence in the runner
system also results in subsurface defect.
4. Another method of reducing cold shut is to modify
alloy composition to enhance fluidity. Remedy
5. Reduce the amount of releasing agent used (Mould
1. To avoid subsurface make adequate provision for
will be less cooled down).
evacuation of air and gas from the mould cavity.
6. Use mould layer that can reduce heat conduction.
2. Increase permeability of mold and cores to reduce
7. Reduce the flow of cooling water or replace the possibility of subsurface.
cooling channel with smaller pipes which results in
controlling this defect. 3. Another method of reducing subsurface is to avoid
improper gating systems
8. Add overflows at appropriate position to increase the
mould temperature. 4. Assure adequate baking of dry sand molds in order to
avoid this defect on casting surface.
11. Subsurface
5. Control moisture levels in green sand molding to
Defects such as small blowholes, pinholes or inclusions
control occurrence of subsurface on casting.
that occur within depths of 3 or 4 mm of the cast surface
among the most difficult to detect. Freedom from such 6. Reduce amounts of binders and additives used or
surface defects is however a very important aspect of change to other types. Use blackings and washes,
quality of casting such defects are frequently revealed at which provide a reducing atmosphere. Keep the spree
late stages in the machining of a component leading to filled and reduce pouring height.
its rejection [7].
7. Increase static pressure by enlarging runner height
Causes which helps to control this defect.
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CONCLUSION

Casting manufacturing involves heavy investment of [2] Rajesh Rajkolhe et al., “Defects, Causes and Their
Remedies in Casting Process: A Review”, International Journal
man, machine and material. Rejection of casting leads to of Research In Advent Technology, Vol.2, No.3, March 2014,E-
heavy losses to casting manufacturers. This being an old ISSN: 2321-9637.
[3] S. Kluska-Nawarecka et al. , “Diagnostics of crack formation in
method, till date problems are tackled using experience castings using the logic of plausible reasoning “Archives of
and hit and trial method. In this paper defects leading to Material Science and Engineering”, Volume 28, Issue 8, August
2007,Pages 479-482.
rejection of Duplex Mould Casting are discussed along
[4] Timothy et al. “Characterization and Correction of Casting
with their causes and remedies which will be helpful to Defects”, Tech Form – Advanced Casting Technology,
all personnel involved in manufacturing of Duplex L.L.C.,1999.
[5] Vaibhav Nerle et al.“Analysis of the Sand Drop Defect to Reduce
Mould Casting and will be immensely beneficial to the Rejection Level of Cylinder Block Casting-A Case Study”,
reduce the rejection of Duplex Mould Casting leading to International Journal of Engineering Research & Technology
(IJERT), Vol. 2 Issue 9, September – 2013.
prevention of huge financial losses faced by Duplex [6] Prof B.R. Jadhav et al. “ Investigation And Analysis Of
Mould Manufacturers. Cold Shut Casting Defect And Defect Reduction By Using 7
Quality Control Tools”, International Journal
of Advanced Engineering Research and Studies July-
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