Such defects can be caused by air entrained in the melt, steam or smoke from the casting sand, or other gasses from the melt or mould. (Vacuum holes caused by metal shrinkage (see above) may also be loosely referred to as blowholes). Proper foundry practices, including melt preparation and mould design, can reduce the occurrence of these defects. Because they are often surrounded by a skin of sound metal, blowholes may be difficult to detect, requiring harmonic, ultrasonic, magnetic, or X-ray (e.g., industrial CT scanning) analysis. Pouring metal defects
Pouring metal defects include misruns, cold shuts, and inclusions. A misrun occurs when the liquid metal does not completely fill the mould cavity, leaving an unfilled portion. Cold shuts occur when two fronts of liquid metal do not fuse properly in the mould cavity, leaving a weak spot. Both are caused by either a lack of fluidity in the molten metal or cross-sections that are too narrow. The fluidity can be increased by changing the chemical composition of the metal or by increasing the pouring temperature. Another possible cause is back pressure from improperly vented mould cavities.Misruns and cold shuts are closely related and both involve the material freezing before it completely fills the mould cavity. These types of defects are serious because the area surrounding the defect is significantly weaker than intended. The castability and viscosity of the material can be important factors with these problems.
Tarsal tunnel syndrome (TTS) is a compression neuropathy and painful foot condition in which the tibial nerve is compressed as it travels through the tarsal tunnel. This tunnel is found along the inner leg behind the medial malleolus (bump on the inside of the ankle). The posterior tibial artery, tibial nerve, and tendons of the tibialis posterior, flexor digitorum longus, and flexor hallucis longus muscles travel in a bundle through the tarsal tunnel. Inside the tunnel, the nerve splits into three segments. One nerve (calcaneal) continues to the heel, the other two (medial and lateral plantar nerves) continue on to the bottom of the foot. The tarsal tunnel is delineated by bone on the inside and the flexor retinaculum on the outside. Patients with TTS typically complain of numbness in the foot radiating to the big toe and the first three toes, pain, burning, electrical sensations, and tingling over the base of the foot and the heel. Depending on the area of entrapment, other areas can be affected. If the entrapment is high, the entire foot can be affected as varying branches of the tibial nerve can become involved. Ankle pain is also present in patients who have high level entrapments. Inflammation or swelling can occur within this tunnel for a number of reasons. The flexor retinaculum has a limited ability to stretch, so increased pressure will eventually cause compression on the nerve within the tunnel. As pressure increases on the nerves, the blood flow decreases. Nerves respond with altered sensations like tingling and numbness.