What Can Affect the Quality of Iron Castings?

The quality of iron castings is very important to the development of an iron foundry, and there are many elements that influence the quality of iron castings, such as design process, casting process, the quality of raw materials and technological operation.

1. Design process of the iron castings

During the design process, in addition to determine the shape and size of iron castings based on the working conditions and the property of metal materials, we should also consider the rationality from the perspective of casting alloy and characteristics of iron castings, that is obvious size effect and solidification, shrinkage, stress and other issues in order to avoid or reduce the casting composition segregation, deformation, cracks and other metal casting defects.

2. Reasonable casting process

The reasonable casting process is very important, that is according to the casting structure, weight and size, characteristics of casting alloy and working conditions, we should choose a suitable parting and molding, core-making method to design casting bars, iron chill, and riser and gating systems.

3. Quality of raw materials

The third is the quality of raw materials used in metal casting. Metal charge, refractory material, fuel, flux, modifier, foundry sand, molding sand binder, paint and other materials, if any of them is not up to standard in quality, air hole, pinhole, slag inclusion, adhering sand and other casting defects will appear, which will affect the appearance and internal quality of castings, even cause casting scrap.

4. Technological operation

The fourth element is the technological operation. A reasonable operation process should be made to develop rules to enhance the technical level of workers, and make sure the engineering procedure to be implemented correctly.

In order to control the quality of iron castings, the inspection is very necessary and important.

First, we should formulate control and inspection codes and engineering factors about the raw materials, auxiliary materials even each specific product process. Each process is strictly controlled and inspected according to inspection codes and technical conditions.

Then, we should inspect the finished castings. We can use reasonable testing methods and allocate appropriate testing staff. About the presentation quality of castings, we can use comparison specimens to judge surface roughness; the hair line on surface can be examined by staining method and magnetic particle method. About the internal quality, we can use frequency, ultrasound, whirlpool, x ray and y ray and other methods to test and judge.

Ultrasonic inspection device

Magnaflux inspection device

X ray testing device

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