![]() ![]() In this work, we present a 3-step approach to casting defect identification, analysis and rectification. For example, if shrinkage porosity is identified as gas porosity, and the pouring temperature is lowered to reduce the same, it may lead to another defect, namely cold shut. Unfortunately, this is not an easy task, since casting process involves complex interactions among various parameters and operations related to metal composition, methods design, molding, melting, pouring, shake-out, fettling and machining. The defects need to be diagnosed correctly for appropriate remedial measures, otherwise new defects may be introduced. Casting defects result in increased unit cost and lower morale of shop floor personnel. Global buyers demand defect-free castings and strict delivery schedule, which foundries are finding it very difficult to meet. ![]() Process parameters, combined with lower penetration of manufacturing automation and shortage of skilled workers compared to other industries. ![]()
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