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Forside › Kvalitet › Støbefejl og hvordan de undgås
Støbefejl og hvordan de undgås
En billedserie viser her eksempler på støbefejl, der kan være vanskelig at undgå fra selv den mest professionelle producent.
Herudover beskrives årsagen. samt hvad der kan gøres for at undgå fejlene.
Casting Defects - Sand Mold, Metal Casting
Introducing various metal casting defects with many pictures from Foundry in China. These are te common sand casting defects on te surface and inside of cast iron and cast steel parts.
1. Blowhole is a kind of cavities defect, which is also divided into pinhole and subsurface blowhole. Pinhole is very tiny hole. Subsurface blowhole only can be seen after machining.
2. Burning-on defect is also called as sand burning, which includes chemical burn-on, and metal penetration.
3. Sand inclusion and slag inclusion are also called as scab or blacking scab. They are inclusion defects. Looks like there are slag inside of metal castings.
4. Sand hole is a kind of shrinkage cavity defect. They are empty holes after sand blasting.
5. Cold lap or also called as cold shut. It is a crack with round edges. Cold lap is because of low melting temperature or poor gating system.
6. Joint flash is also called as casting fin, which is a thin projection out of surface of metal castings. Joint flash should be removed during cleaning and grinding process.
7. Misrun defect is a kind of incomplete casting defect, which causes te casting uncompleted. Te edge of defect is round and smooth.
8. Shrinkage defects include dispersed shrinkage, micro-shrinkage and porosity.
9. Shrinkage cavities are also called as shrinkage holes, which is a type of serious shrinkage defect.
10. Shrinkage depression is also a type of shrinkage defect, which looks like depressed region on te surface of metal castings.
11. Elephant skin is a type of surface defect, which cause irregular or wrinkle shapes surfaces.
12. Veins defect is also called as rat tail, which looks like many small water flow traces on te surface of metal castings.
13. Rough surface, coarse surface is also a kind of surface defect. Normal rough surfaces can not be judged as defects, but too rough and uneven in surface will be a defect.
14. Mismatch in mold defect is because of te shifting molding flashes. It will cause te dislocation at te parting line.
15. Mechanical damage is because te damage during machining or delivery processes.
16. Slag inclusion is also called as exogenous inclusion, entrapped slag.
17. Raised mold defect. Because of te flotage of liquid metal, te mould flasks are raised, which caused te top part of casting become higher or thicker than lower part.
18. Crack defects normally happen inside of metal castings. This defect will reduce te physical properties of metal castings.
19. Abnormal nodulizing or under-nodulizing defects. Because of many reasons, te spheroidization of graphite for ductile iron will be affected, therefore, caused te bad spheroidization rate.
20. Uneven hardness defect means te uneven hardness on te same surfaces. When machining to harder positions, te machining will become more difficult.
21. Sand drop is also called as sand crush. Te sand mold drops part of sand blocks, so they will cause te similar shaped sand holes or incomplete.
22. Deformation will cause te oversized tolerance for flatness and straightness. This is very common defect for long castings, and flat castings with thin wall thickness. Te reasons are te natural deformation during cooling process in sand molds, or in air, sometimes, te overly sand blasting also could cause this problem.
23. After welding repair, even after machining or grinding, te welding marks will still be visual. As for unimportant casting surfaces, if te client allow welding repair, then these marks should be acceptable. But for high pressure-bearing positions, or te client has clearly forbidden any welding repair, then these marks will be taken as defects.
24. Chill iron could effectively reduce te shrinkage for te key positions, so using chill iron is very common in iron foundries. However, te edges of chill irons could be clearly found by visual inspection. Some clients will not require to grind them if these marks do not affect te appearance. However, te clients could require te casting manufacturer to grind them just for better surface looking. Please clearly notice that these marks should not be judged as te casting defects. Refer to iron-foundry.com.
25. Chill defects are also called as "casting chilling defects". Te surface of te castings with this defect will be extremely white, shiny and smooth. Te left one of te parts on te following photo is showing this defect. Te defective castings will be fragile and crispy, so during machining, some edges and tips will be broken. This defect was caused by te low temperature of sand molds, and prematurely out of sand molds, so te hot iron become chilled quickly. Te proper annealing heat treatment to them could solve this defect.
26. Massive free carbide. This is a defect of material, normally happen on ductile iron. Because of inverse chilling defects and poor inoculation, there will be mass free carbide, which will cause fragile, poor welding property to ductile iron castings. High temperature annealing heat treatment could improve it.
27. Internal sweating, or called as cold short, short iron. There are iron beans in te castings. This is because of unreasonable gating design, which caused some liquid iron became beans suddenly, then these beans were wrapped by other liquid irons. This is a surface defect, but will cause serous problem if they located in key positions.
Internal sweating, cold short, short iron
28. Stripping defect. There is very thin iron skin on te surface of castings. Two layers. This is because of unreasonable gating system, which caused very thin air layers existed. This defect is a surface defect, so normally it can be grinded off. However, it should be discarded if it is not just on te surface.
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