In this current scenario of globalization, foundries play a key role for manufacturing industries as they are the major source of castings. As a key industry a foundry’s performance should be effectively high in terms of production with minimum number of rejections. Castings are the major inputs for most industrial products hence foundry industry is most indispensable. Casting is an integrated process considered as an artwork with experienced professionals for high quality yield, even then in highly controlled environment defects are dominant to take place leading to rejections, contrary to rejections a foundry’s key attempt is to satisfy the demands neglecting quality levels. The challenges of casting defects are to be identified and minimized for effective castings. This study provides an intense knowledge of critical casting defects and their root cause analysis. In this paper efforts are made to achieve technically feasible remedies for minimizing several casting defects and improving the quality of castings which will serve as control measures for quality control professionals with zero defect concepts.
Defects formation in castings is one of the most vexed topics of foundry industries. Foundry industries
mostly rely on different process parameters to control such defects ensuring high efficacy of casting with an
optimum yield hence controlling of such parameters becomes necessary by sound knowledge of possible causes,
for this the probable defects should be analyzed and their root causes have to be studied. This paper brings out the industrial case study of castings having prominent defects. The work was carried out based on production trials. An attempt has been made to analyze the critical defects and possible remedial measures are suggested for cast masters to have a sound knowledge about such defects with an aim to minimize rejections rates. The data was
collected to take decisive action for quality improvement with reduced rejection in castings.