Casting flaws in metal can be functional or cosmetic and can be prevented by using qualified personnel and proper equipment. Defects include bubbles, gaps, and contamination, which weaken the metal. Technicians may repair flaws if it doesn’t compromise the integrity of the metal, otherwise, scraps can be recycled.
A casting flaw is a functional or cosmetic flaw in a piece of cast metal. There are numerous types of defects that people can observe in molten metal, and steps can be taken to prevent defects or fix them once they arise. Using qualified personnel and proper equipment is an important step in making the casting process as effective as possible, as many defects are the result of improper handling of materials during casting, and people can avoid them with proper training.
Sometimes, tiny bubbles form during casting, making the metal porous. This creates weak spots that can give way under stress. Larger air pockets can also form that are sometimes not easily visible because they are within the metal, rather than along the edges of the finished piece where people can easily see them. The metal may fail to fill a die, creating a gap, or overflow, creating a seepage that someone will have to cut through.
A casting defect can also result in unequal cooling rates in the mold, creating lines where the metal does not melt completely. These are weak, and if the metal is under stress, it can bend or break at those points. Contamination in the mold can also contribute to casting defects, leaving flecks of other materials in the finished product or creating a weak spot by triggering chemical reactions that change the composition of the product while the metal is in its liquid state. People working with alloys may encounter problems with poor mixes or contamination, leading to poor in-die performance and a subsequent casting defect.
Creating cast metal pieces requires using the proper dies, heating the metals to the correct temperature, and handling the dies properly during the casting process. Many mistakes can lead to a casting defect. Sometimes they are just plain unsightly and don’t interfere with the function of the finished piece. Others can create a problem by weakening the metal. Casters use material tests to check the quality of the finished products, looking for any defects that might make it necessary to scrap the part.
If it is possible to finish or machine the part to repair the casting flaw without compromising the integrity of the metal, a technician may consider this option. This needs to be weighed against the cost of hiring someone to fix the problem. The scraps can be melted down and recycled, sold in seconds to people who don’t need perfect pieces, or sold to recycling companies for another facility to use.
Protect your devices with Threat Protection by NordVPN
