{"id":3082,"date":"2020-03-24T08:44:49","date_gmt":"2020-03-24T08:44:49","guid":{"rendered":"http:\/\/hengkemetal.com\/?p=3082"},"modified":"2022-12-12T04:55:52","modified_gmt":"2022-12-12T04:55:52","slug":"avoiding-defects-in-investment-casting","status":"publish","type":"post","link":"https:\/\/www.hengkemetal.com\/avoiding-defects-in-investment-casting\/","title":{"rendered":"Avoiding Defects in Investment Casting"},"content":{"rendered":"<p>[vc_row][\/vc_row][vc_column css=&#8221;.vc_custom_1560701587242{padding-bottom: 50px !important;}&#8221;][\/vc_column][vc_column_text]<span style=\"font-weight: 400;\">Avoiding Defects in Investment Casting<\/span><\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-weight: 400;\">Manufacturing processes for investment casting include a series of operations that expose the green casting to heat and pressure.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">\u00a0These factors, coupled with the properties of the alloy powders and the design of the final casting, make certain defects inevitable.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">While there is no doubt that the investment casting process benefits a wide range of industries, all may not be perfect.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Critical industries such as aerospace casting services and automotive investment casting services need proper ways of identifying casting defects and causes.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">To enjoy the full investment casting benefits, we are going to learn more about avoiding defects in the investment casting process.<\/span><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<div id=\"toc_container\" class=\"no_bullets\"><p class=\"toc_title\">Contents<\/p><ul class=\"toc_list\"><li><a href=\"#Shrinkage\"><span class=\"toc_number toc_depth_1\">1<\/span> Shrinkage<\/a><\/li><li><a href=\"#Aluminum_casting_defects\"><span class=\"toc_number toc_depth_1\">2<\/span> Aluminum casting defects<\/a><\/li><li><a href=\"#Die_casting_defects\"><span class=\"toc_number toc_depth_1\">3<\/span> Die casting defects<\/a><\/li><li><a href=\"#Porosity_in_investment_casting\"><span class=\"toc_number toc_depth_1\">4<\/span> Porosity in investment casting<\/a><\/li><li><a href=\"#Preventing_defects_using_ultrasonic_flaw_detectors\"><span class=\"toc_number toc_depth_1\">5<\/span> Preventing defects using\u00a0 ultrasonic flaw detectors<\/a><\/li><li><a href=\"#How_a_flaw_detection_works\"><span class=\"toc_number toc_depth_1\">6<\/span> How a flaw detection works<\/a><\/li><li><a href=\"#Choose_reputable_investment_casting_manufacturer_and_suppliers_in_China\"><span class=\"toc_number toc_depth_1\">7<\/span> Choose reputable investment casting manufacturer and suppliers in China<\/a><\/li><li><a href=\"#Conclusion\"><span class=\"toc_number toc_depth_1\">8<\/span> Conclusion<\/a><\/li><\/ul><\/div>\n<h2><span id=\"Shrinkage\"><b>Shrinkage<\/b><\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Shrinkage is a defect associated with insufficient heat when the casting is poured, which results in a cavity in the casting.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">When the casting cools down, the molten metal shrinks, leaving an empty space in the mold. This defect can be avoided by making sure the pouring temperature is high enough.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Visually, you can identify shrinkage defects as a bubble or a hollow area in the casting. On the X-ray, these areas appear as a dark object. In many cases, the defect is so large that the casting cannot be repaired.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">\u00a0The best way to avoid shrinkage defects is to control the pouring temperature in the investment casting process.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Make sure the investment casting molten metal is at a temperature of 1,150\u00b0 Fahrenheit or higher. You can also make use of a good-quality temperature gauge to measure the pouring temperature.<\/span><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<h2><span id=\"Aluminum_casting_defects\"><b>Aluminum casting defects<\/b><\/span><\/h2>\n<p><span style=\"font-weight: 400;\">When used for castings, aluminum alloys may suffer from a number of defects. These defects may include porosity, cold shut, Gas-Porosity and inclusion.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">&#8211; Porosity: This defect occurs when air or gases are trapped inside the casting. Porosity can be caused by oxidizing sand, high pouring temperature, dirty equipment, etc. To reduce the chances of getting a porous casting, use clean sand, keep the pouring temperature low, and use a vacuum pump to remove gases from the mold.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">&#8211; Cold shut: This defect occurs when the aluminum alloy freezes inside the mold. This happens when the casting temperature is too low. To avoid this defect, keep the casting temperature as high as possible.\u00a0<\/span><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><b>Cold shut defect in casting<\/b><\/p>\n<p><span style=\"font-weight: 400;\">Cold shut is an aluminum casting defect that occurs when the cool down rate of the casting is too slow.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">\u00a0It can also be caused by a sudden change in the cooling rate, but this is less common.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">When the cooling rate is too slow, the molten aluminum contracts and squeezes the molten slag out of the mold.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Eventually, it will come into contact with the water inside the mold and freeze. The surface of the mold freezes before the aluminum does, which causes the surface of the aluminum to become brittle.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">If the surface of the mold breaks before the aluminum cools, the aluminum will contract, creating a crack.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">To avoid cold shut defects, make sure to cool the mold slowly. If possible, use a water-cooled mold to cool the casting more quickly. If you\u2019re using a water-cooled mold, make sure the water is clean and doesn\u2019t have any impurities in it.<\/span><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><b>Sand casting defects<\/b><\/p>\n<p><span style=\"font-weight: 400;\">Sand casting defects are often the result of poor design, but they can also be the result of impurities in the sand. They can negatively impact the strength and surface finish of the casting.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Gas Porosity: This defect occurs when air and gases inside the mold combine with molten aluminum to form bubbles. To avoid this defect, make sure the mold is dry, and the molten aluminum doesn\u2019t come into contact with water.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Inclusions: This defect occurs when impurities are present inside the\u00a0 sand casting. To avoid this defect, make sure the sand used in the mold is clean and dry, and use a clean ladle to pour aluminum into the mold.<\/span><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<h2><span id=\"Die_casting_defects\"><b>Die casting defects<\/b><\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Die casting defects include uneven cooling, which creates an unbalanced casting, and wrinkling, which occurs when the molten metal is trapped in the die.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">\u00a0Both defects negatively affect the surface finish of the castings.\u00a0<\/span><\/p>\n<p>&nbsp;<\/p>\n<h2><span id=\"Porosity_in_investment_casting\"><b>Porosity in investment casting<\/b><\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Porosity is an opening in the casting caused by trapped gases that are released during the solidification process.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">\u00a0This defect negatively affects the strength and integrity of the castings.\u00a0<\/span><\/p>\n<p>&nbsp;<\/p>\n<h2><span id=\"Preventing_defects_using_ultrasonic_flaw_detectors\"><b>Preventing defects using\u00a0 ultrasonic flaw detectors<\/b><\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Ultrasonic flaw detectors are designed to scan your investment casting parts and components to find defects such as inclusions, voids, and cracks.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">\u00a0By scanning the parts before and after the casting process, you can better control for potential defects that could appear during the process.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">The standard investment casting process may expose the parts to up to 7,000 psi of pressure.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">\u00a0This can create internal flaws that are difficult to detect using standard inspection techniques. The ultrasonic flaw detectors can detect internal flaws that would otherwise go unnoticed.<\/span><\/p>\n<p>&nbsp;<\/p>\n<h2><span id=\"How_a_flaw_detection_works\"><b>How a flaw detection works<\/b><\/span><\/h2>\n<p><span style=\"font-weight: 400;\">A flaw detection is used for part inspection and quality control. It is specifically designed to find internal flaws in your parts, which are very difficult to find by visual inspection. The powerful combination of high-frequency sound waves and electrical current penetrates the surface of the part to look inside.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">This allows the flaw detector to identify defects such as porosity, inclusions, cracks, and voids.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">The data from the flaw detection is fed into the CAM system to generate a soundness map.<\/span><\/p>\n<p>&nbsp;<\/p>\n<h2><span id=\"Choose_reputable_investment_casting_manufacturer_and_suppliers_in_China\"><b>Choose reputable investment casting manufacturer and suppliers in China<\/b><\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Because investment casting is such a mature process, you have a wide range of options in terms of manufacturer and supplier. It is important to conduct due diligence with each company you consider to ensure you have a positive experience.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Some key factors to keep in mind when selecting a manufacturer include their equipment, staff experience, and service capabilities.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Make sure the company you choose has the proper equipment for your part, including the right size and configuration of the molds and the proper type of furnace.<\/span><\/p>\n<p>&nbsp;<\/p>\n<h2><span id=\"Conclusion\"><b>Conclusion<\/b><\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Investment casting is a tried-and-true method of creating durable, complex parts. It is almost entirely immune to the effects of heat and pressure, making it ideal for intricate parts that might be damaged by traditional machining methods.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">This article has covered the basics of how to avoid defects in the investment casting process.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">There are ways to manage these risks in your operation through a combination of material selection and risk mitigation techniques.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Check out our website for more investment casting defects and remedies pdf.<\/span><\/p>\n<p><iframe loading=\"lazy\" title=\"Casting Defects and Remedies | How to prevent casting defects | Casting Definition | Defects Types\" width=\"1200\" height=\"675\" src=\"https:\/\/www.youtube.com\/embed\/pNsZ4-So4n4?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture\" allowfullscreen><\/iframe><\/p>\n<p>[\/vc_column_text]<\/p>\n<div style=\"display: none;\"\n    class=\"kk-star-ratings kksr-valign-bottom kksr-align-left \"\n    data-id=\"3082\"\n    data-slug=\"\">\n    <div class=\"kksr-stars\">\n    <div class=\"kksr-stars-inactive\">\n            <div class=\"kksr-star\" data-star=\"1\">\n            <div class=\"kksr-icon\" style=\"width: 24px; 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