Experimental study of foundry defects in aluminium castings for quality improvement of casting

Every industry objective is to improve quality as well as productivity of manufacturing product. Casting defects is one and the only limitation in any casting process. Sand casting process too suffers from the same problem. Finding out the optimum condition towards acquiring minimum casting defects is very critical. The normal method that most of the companies use is the trial and error method. But due to limitations like error prone results, expensive and time consuming, this method causes too much cost to company. In this paper, an attempt has been made to minimize the casting defects by following right practices in the sand casting process. It was found from Casting defects and their remedies that defects can be minimised by controlling the quality of moulding sand such as sand grain size, clay content and moisture percentage. From sand testing, it was found that the clay content in the moulding sand was very high and the size of sand particles was coarse. It resulted in various sand casting defects such as blow holes, shrinkage, sand inclusions, etc. It is very important to provide preventive action to improve quality as well as productivity an industrial level. By following right practices such as proper melt treatment, optimum sand quality, right pouring temperature the sand casting defects can be reduced successfully.