The moulding sand becomes incorporated into the casting metal and decreases the ductility, fatigue strength, and fracture toughness of the casting. This can be caused by a sand with too little strength or a pouring velocity that is too fast. The pouring velocity can be reduced by redesigning the gating system to use larger runners or multiple gates. A related source of defects are drops, in which part of the moulding sand from the cope drops into the casting while it is still a liquid. This also occurs when the mould is not properly rammed.The second type of defect is metal penetration, which occurs when the liquid metal penetrates into the moulding sand. This causes a rough surface finish. This is caused by sand particles which are too coarse, lack of mould wash, or pouring temperatures that are too high. An alternative form of metal penetration into the mould known as veining is caused by cracking of the sand. If the pouring temperature is too high or a sand of low melting point is used then the sand can fuse to the casting. When this happens the surface of the casting produced has a brittle, glassy appearance.A run out occurs when the liquid metal leaks out of the mould because of a faulty mould or flask.Scabs are a thin layer of metal that sits proud of the casting. They are easy to remove and always reveal a buckle underneath, which is an indentation in the casting surface.
In larger casting, they can be up to a millimetre (0.040 in) in diameter.To prevent gas porosity the material may be melted in a vacuum, in an environment of low-solubility gases, such as argon or carbon dioxide, or under a flux that prevents contact with the air. To minimize gas solubility the superheat temperatures can be kept low. Turbulence from pouring the liquid metal into the mould can introduce gases, so the moulds are often streamlined to minimize such turbulence. Other methods include vacuum degassing, gas flushing, or precipitation. Precipitation involves reacting the gas with another element to form a compound that will form a dross that floats to the top. For instance, oxygen can be removed from copper by adding phosphorus; aluminium or silicon can be added to steel to remove oxygen. A third source consists of reactions of the molten metal with grease or other residues in the mould. Hydrogen is produced by the reaction of the metal with humidity or residual moisture in the mould. Drying the mould can eliminate this source of hydrogen formation.Gas porosity can sometimes be difficult to distinguish from micro shrinkage because microshrinkage cavities can contain gases as well. In general, microporosities will form if the casting is not properly risered or if a material with a wide solidification range is cast. If neither of these are the case then most likely the porosity is due to gas formation. Tiny gas bubbles are called porosities, but larger gas bubbles are called blowholes or blisters.