Casting defects

Gallo R

Transactions of the American Foundry Society, Volume 109, Pages 1-19, 2001

Abstract: This article presents a case study in which a design of experiment (DOE) was conducted before the defects were properly identified. The purpose is to reflect on the methodology and cultural thinking of a jobbing foundry to eliminate metallurgical defects in a particular automotive green sand casting. This article also demonstrate how improper diagnosis of defects lead the experiment the wrong path yielding ambiguous results. In addition , it clearly shows the benefits of scanning electron microscopy (SEM) analysis for evaluation of the metallurgical defects. Furthermore, it provides practical knowledge regarding identification of casting defects with scanning electron photo micrographs. Finally, it will emphasize the importance of proper defect analysis before a corrective action is considered.

Keywords: Casting, Defects, Defect analysis, Design of experiment, Foundry, Green sand casting .