Authors : A.G.Thakare , Dr.D.J.Tidke
Abstract – Casting defects are usually easy to characterize but to eradicate them can be a difficult task. Defects are the result of combination of different factors whose identification is often a very difficult task. Casting is a complex process which involves complex interactions among various parameters and operations related to metal composition, methods process, melting, pouring, machining. Presence of these defects exposes foundries to contribute over 70% of total quality costs. Foundries try to reduce rejections by experimenting with process parameters, when this is ineffective they try to modify methods design, when this fails then they try to modify tooling design. So approach of foundries is completely on trial and error basis. Foundries must try to reduce rejections by systematically finding the reasons responsible for occurrence of defects and analyze them. In this paper analysis of defects in Duplex Mould Casting has been carried out. All the major defects in Duplex Mould Casting along with causes and remedies have been discussed. This will be helpful to quality control engineers for root cause analysis and finding correct remedial action so as to avoid the defects before they result in rejection of Duplex mould casting, which is very costly affair.
