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Slag Inclusions In Steel Castings: Where They Come From And How To Stop Them
A batch of castings fails inspection. The surface looks clean, but X-ray or machining reveals dark, irregular patches buried beneath. These slag inclusions cost you yield, rework hours, and a difficult conversation with your customer. If you are reviewing a defect...
Why Risers Fail: 6 Reasons A Riser Stops Feeding Your Casting
You cut open the casting and find shrinkage porosity sitting right under the riser you sized, placed, and calculated with care. The riser modulus checked out. The feeding distance looked fine on paper. So why did it still fail?A riser fails when one critical link in...
How To Reduce Shrinkage Porosity In Aluminum Castings Without Changing Your Mould
Every foundry engineer knows the sinking feeling when X-ray results show that cluster of shrinkage porosity in the exact same spot again. Your first instinct might be to blame the tooling, but most aluminum casting Shrinkage defects are process control problems...
5 Types Of Foundry Sand And How Each One Changes Your Casting Quality
That scrap casting sitting on your shop floor with the unexplained gas porosity might have nothing to do with your melt chemistry. More often than engineers want to admit, the real culprit sits in the molding sand hopper.Foundry sand is far from an off-the-shelf...
Porosity Vs Shrinkage Cavity In Castings: How To Tell Them Apart On A Cut Section
You cut the casting open to find a cluster of dark, round voids staring back at you. Whether it's gas porosity or shrinkage, the part fails inspection either way. The fixes couldn't be more different, though, and guessing wrong means chasing the wrong root cause for...
Metal Casting Shrinkage: What Actually Causes It And How Foundries Eliminate It
A casting comes out of the mold looking perfect. Then QC cuts it open, or worse, it fails in service, and there's a cavity sitting right where the wall was thickest. metal casting shrinkage is pure physics. Every alloy contracts through three distinct stages as it...
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