How the formation of casting defects
2013-06-16 11:53:03

   

Casting defects should first determine what causes. Cracks caused by many reasons, have the following common                                                                                                                                                                                           

1,Stoma

Feature, the pore often take place interiorly, some smooth air hole exist in the surface or subsurface. Sidewall sometimes exhibits oxidation colour. Because the gas come from different source and different forming reason, the exibit different formation, such as ingressive pore, precipitation pore, subsurface pore.

2,Sand hole, inclusion hole

Feature: in inner or on the surface of the defect location, some hole fill with sand which called sand hole. If the defect represent irregular formation, and filling with residue or inclusion, which called inclusion hole.

3,Shrinkage or looseness

Feature: on the thick section of casting, hot spot or the axis center of the last freezing location, rough holes often take place, and more or less formed dendrite. Big and concentrated holes are called shrink, small and scattered are called looseness. The reduction in liquid shrink is more bigger than in solid shrink during the metal liquid turning into solid, and in the last location of freezing, no metal liquid can be available for compensation.

4,Adhering

Feature: on the surface of the casting, there is a layer of model material, which is different to remove. Including mechanical and chemical adhesive. The difference between these: mechanical adhesive is formed when the high temperature metal liquid enter into the gap among sands; when metal is oxidized and combined with the model material and form a combination with low melt temperature, and bonded firmly 

5,Crack

Feature: straight and curving crack take place in the casting surface. Involving Hot crack and cold crack. Hot crack breach mostly appear flexural and irregular form, and the cross section appear light black, and deep color oxidation. The breach of cold crack appears straight section, and have metal sheen and clear, sometimes appear slightly oxidation color. 
The reason of occurring crack is when the reduction is resistant by the inner stresss when freezing, and when the inner stress is bigger than the metal tensile, the crack will occur.
 
6,Deformation
Feature: longer castings are easy to deform, such as lathe bed, cylinder of diesel engine, cover, because of too much difference of the thickness, cooling no uniformly, this will result in casting deformation. Some castings represent deformation after machining finished and stored for some time. 
 
7,Hardness uneven
Feature: after machining, some protrude or/and concave points appear, some location have highlight hard point, the surface has bigger differential hardness, it can reach to 30-50HB,(advanced level 5-10HB), the hardenss of the hard point may exceed the standard. The difference of hardness will cause the uneven working face, and result in inaccurate of the lathe machining, make a big noise on diesel engine

 

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