The Effect of a Thin-Wall Casting Mould Cavity Filling Conditions on the Casting Surface Quality

Open access


The paper presents results of metallographic examination of faults occurring in the course of founding thin-walled cast-iron castings in furan resin sand molds. A non-conformance of the scab type was Observed on surface of the casting as well as sand buckles and cold shots. Studied the chemical composition by means of a scanning electron microscope in a region of casting defects: microanalysis point and microanalysis surface. Around the observed defects discloses high concentration of oxides of iron, manganese and silicon. A computer simulation of the casting process has been carried out with the objective to establish the cause of occurrence of cold shots on casting surface. The simulation was carried out with the use of NovaFlow & Solid program. We analyzed the flowing metal in the mold cavity. The main reason for the occurrence of casting defects on the surface of the casting was gating system, which caused turbulent flow of metal with a distinctive splash stream of liquid alloy.

[1] Fraś, E., Górny, M. & Kapturkieiwcz, W. (2013). Thin wall ductile iron castings: technological aspects. Archives of Foundry Engineering. 13(1), 23-28.

[2] Fraś, E., Górny, M. & Lopez, H. (2014). Thin wall ductile iron castings as substitutes for aluminium alloy castings. Archives of Metallurgy and Materials. 59(2), 459-465.

[3] Górny, M. (2009). Thin wall ductile iron castings as substitute for aluminium alloy casting in automotive industry. Archives of Foundry Engineering. 9(1), 143-146.

[4] Vasková, I., Fecko, D. & Malik, J. (2012). The Dependance of Castings Quality Produced into the Clay Moulding Mixtures from the Properties of Binder on the Montmorillonite. Archives of Foundry Engineering. 12(3), 121-126.

[5] Mocek, J. (2003). The process of erosion of sand moulds prepared with water glass binding. Archives of Foundry. 3(10), 23-30.

[6] Mocek, J. (2001). Influence of selected technological factors on erosion of sand moulds poured with cast iron. Archives of Foundry. 1(1 2/2).

[7] Mocek, J. & Samsonowicz, J. (2011). Changes of gas pressure in sand mould during cast iron pouring. Archives of Foundry Engineering. 11(4), 87-92.

[8] Chojecki, A. & Mocek, J. (2008). Erosion phenomena in sand moulds. Archives of Foundry Engineering. 8(spec.1), 49-52.

[9] Mocek, J. (2002). Erosion of the sand moulds during filling by liquid cast iron. Archives of Foundry. 2(5), 100-105.

[10] Falęcki, Z. (1991). Analysis of casting defects. Kraków: the script AGH No. 1283.

[11] Fras, E., Podrzucki, Cz. (1978). Cast iron modified. Kraków: the script AGH, No. 675.

[12] Murgas, M. & Pokusova, M. (2007). Grafitizacno ockovadlo pre sinteticku liatinu. Sbornik vedeckich praci. Vysoka skola banska Technicka Universita v Ostravie. 50(1), 173-178.

Archives of Foundry Engineering

The Journal of Polish Academy of Sciences

Journal Information

CiteScore 2016: 0.42

SCImago Journal Rank (SJR) 2016: 0.192
Source Normalized Impact per Paper (SNIP) 2016: 0.316


All Time Past Year Past 30 Days
Abstract Views 0 0 0
Full Text Views 153 148 6
PDF Downloads 62 61 3