Casting Defect Analysis

Introduction to Casting Defect Analysis

This module is divided into three parts:
•    Part 1: Meet Metro Metalcasting, Inc.
•    Part 2: Categorize Casting Defects
•    Part 3: Analyze Casting Defects

Part 1 of this module is an introduction to Metro Metalcasting, Inc. (a fictional company) that is experiencing a high percentage of casting defects. Through the solutions team, participants are introduced to the 10-Step Procedure, a systematic approach to analyzing and reducing casting defects. In Part 2, the seven categories of casting defects are described and participants will become familiar with the “International Atlas of Casting Defects.” In Part 3, participants will learn how to use the 10-Step Procedure to resolve a casting defect. You will be introduced to the tools used in each of the 10 steps and how to implement them. By the end of this module, you will be able to identify the 10-Step Procedure and use these steps to analyze a casting defect. (0.3 CEU)

Gas Related Defects

In this module, the many sources of gas-related defects and the three types of gas-related defects are identified. This module also identifies the causes of these three types of defects and control measures that can be made at your facility. By the end of this module, you will be able to list the three types of gas-related defects and two control measures for each gas-related defect. (0.1 CEU)

Oxide Related Defects

In this module, the different types of oxide-related defects are defined and identified. This module also identifies the oxide-related defect causes and control measures to combat these defects. There is a brief examination of certain gating system topics to understand how oxides can be affected by the gating system. By the end of this module, you will be able to identify the types of oxide-related defects and list two control measures for preventing oxides. (0.1 CEU)

Sand Related Defects

The sand molding process and the four types of sand casting methods are identified in this module. Three different types of sand-related defects: sand expansion, sand adhesion, and sand strength are reviewed. Along with in-depth explanations of these defects, possible sand system control measures are discussed to help avoid these defects. By the end of this module, you will be able to identify the three-different types of sand-related defects and one control measure to implement per sand-related defect. (0.2 CEU)

Shrink Related Defects

In this module, shrinkage and the different types of shrink-related defects are identified. This module also identifies the causes of these shrink-related defects. In addition, shrink defects are distinguished from gas defects and shrink control measures are described. The module briefly examines some gating system topics and how shrinkage can be affected by the gating system. By the end of this module, you will be able to identify the types of shrink-related defects and list two control measures for preventing shrink defects. (0.1 CEU)

Casting Defect Analysis Practice and Conclusion

This module focuses on the practice of using the 10-Step Procedure to analyze a casting defect. This module is the culmination of the previous five modules. AFS recommends the completion of the following modules before taking this module:
•    Introduction to Casting Defect Analysis
•    Gas-related Defects
•    Oxide-related Defects
•    Sand-related Defects
•    Shrink-related Defects
By the end of this module, you’ll be able to identify the 10-Step Procedure and use these steps to analyze a casting defect. (0.1 CEU)

Aluminum Casting Defects: Gas Porosity and Shrinkage Porosity

In this module, the difference between gas porosity and shrinkage porosity is examined along with causes and the methods to control them. Upon completion of this module, you will be able to define macro and micro porosity shrinkage aluminum defects and identify two control methods to reduce defects. (0.1 CEU)

Cast Iron Defects: Solidification Shrinkage in Gray Cast Iron

This module focuses on the factors that affect solidification shrinkage in gray iron. Topics discussed include: the differences between pure iron and graphitic cast irons; the unique characteristics of gray irons; the range of behavior for gray irons over the normal range of carbon equivalent (C.E.); the effects of solidification shrinkage on casting quality and defect appearances; and some steps and considerations to reduce the risk of solidification shrinkage defects. By the end of this module, you will be able to identify two control measures for reducing solidification shrinkage in gray cast irons. (0.1 CEU)

Copper Casting Defects: Shrinkage

In this module, shrinkage porosity is defined and various shrinkage porosity characteristics and classifications are identified (e.g., size, distribution, location, and performance). By the end of this module, you will be able to define macro and micro porosity shrinkage copper casting defects and identify two control methods to reduce those defects. (0.1 CEU)

Introduction to Green Sand Defects

In this module, the visual inspection and physical properties needed to look at green sand defects are identified. This module also describes the causes of common green sand defects. By the end of the module, you will be able to identify one shrinkage defect, one gas porosity defect, one sand adherence defect, one sand strength defect, and one sand expansion defect. (0.1 CEU)

Steel Casting Defects: Shrinkage

The two types of steel shrinkage defects, macro and micro shrinkage porosity (voids), are explored in this module. This module also identifies control measures to reduce or eliminate shrinkage defects. By the end of this module, you will be able to define macro and micro shrinkage porosity (voids) defects in steel and identify two control methods to reduce the defects. (0.1 CEU)