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IS 12880 (1989): Guidelines for Controlling Foundry


Rejection [MTD 14: Foundry]

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Satyanarayan Gangaram Pitroda
Invent a New India Using Knowledge

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BharthariNtiatakam
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IS 12880 : 1989
( Reafliiaed 2000)
(Reaffirmed 199s )

Indian Standard
*
GUIDELINES FOR CONTROLLING
FOUNDRY REJECTION

( First Reprint AUGUST 1998 )

UDC 62174019

0 BIS 1990

BUREAU OF INDIAN STANDARDS


MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARC
NEW DELHI 110002

September 1990 Price Group 3


Foundry Sectional Committee, MTD 14

FOREWORD

This Indian Standard was adopted by the Bureau of Indian Standards on 8 December 1989, after
the draft finalized by the Foundry Sectional Committee had been approved by the Metallurgical
Engineering Division Council.

There is a large number of foundries in the country, producing iron and steel castings catering to a
wide range of customers, automobile and other engineering fields for domestic and overseas
market.

It has been observed that return in terms of good castings is less in comparison with the inputs in
terms of capital investment, manpower, raw material and power utilization.

Considering the low return in the foundry industry to be a gross national loss, attempts have been
made to prepare suitable guidelines for reducing foundry rejection.

The information given in this standard should serve as good guidelines. However, reasonable
knowledge about the technology, constant vigilance and effective pursuance are necessary to keep the
rejections under control and to improve upon the condition.

In case of increase in rejections, A B C analysis shall be done on the causes of rejection. Then the
priority shall be set to deal with accordingly. Economic considerations shall not be lost sight of in
an attempt to reduce rejection. At times, it is found that while solving one problem another crops
in or in an attempt to solve a minor increase in rejection the steps taken have involved higher cost
than the cost of rejection.

The nature and the extent of defects shall be decided on the basis of the end use of the product and
shall be as agreed to between the purchaser and the supplier. Doubtful cases shall be subjected to
field trials and the standard for rejection shall be updated accordingly.

Scrap diagnosis chart for some common defects in iron castings, their causes and remedies is given
in Annex A.

It is needless to mention that suitable reclamation techniques, such as, welding, brazing, etc, along
with pre- and post-salvaging treatments also contribute towards bringing down the rejection.

Micro porosity or micro shrinkage causing leakage under pressure test shall be sealed by impreg-
nation technique wherever permitted.

In the preparation of this standard valuable assistance has been provided by TELCO, Jamshedpur.
1s 12880:1989

Indian Standard
GUIDELINES FOR CONTROLLING
FOUNDRY REJECTION
1 SCOPE 5.2 Weekly and Monthly Inspection Report

1.1 This standard lays down the guidelines, in Weekly and monthly rejections shall be reported
general, towards saving rejection in foundry. as percentage of the total rejection as well as the
break-ups under individual categories and defects.
The report shall have the cumulative status in the
2 REFERENCES
week as well asin the month comparing rejectior
of the previous week and month.
2.1 The following Indian Standards are necessary
adjuncts to this standard:
5.3 Master Chart
IS No. Title
The master chart shall indicate item-wise rejection
210 : 1978 Grey iron castings ( third revision)
of the day, cumulative till date of the month,
6331 : 1987 Automotive grey iron castings previous month, cumulative till date of the year,
previous year and all time best achieved.
3 ACHIEVABLE REJECTION LEVELS AT
FOUNDRY AND MACHINE SHOP 6 METHOD CARD

3.1 Ordinary grey iron castings shall conform to 6.1 Once a casting drawing is finalized for pro-
IS 210 : 1978 and high duty castings shall con- duction, the mould scheme/core setting/core
form to 1s 6331 : 1987 having simple shape with assembly system must be indicated in a card.
no core or simple cores. The rejections shall be The card shall have a rough sketch of the casting
as follows: indicating gating system and core setting arrange-
ment vent positions. lnformation shall also be
Attainable Foundry AttainabZe Machine available regarding the type of moulding machine,
Rejections Shop Rejections boxes to be used, grade of metal, sand pouring
temperature, pouring time, composition for mould
3 percent, Max 1 percent, Max and cores, wash practice, etc. During early stage
of production trials, relevant data regarding
3.2 For metal quality same as stated in 3.1 but rejection, physical properties and chemical com-
the castings having complicated outer as well as position shall be recorded against each trial.
inner profiles, such as, automobile castings, the Changes even seemingly insignificant ones at any
rejections shall be as given below: stage of production shall be recorded and incor-
Attainable Foundry Attainable Machine porated with the knowledge of all the concerned
Rejections Shop Rejections departments.

5 percent, Max 2 percent, Max 6.2 Results obtained from the production trrals
vis-a-vis practices adopted shall be discussed and
4 BASIS OF REJECTION REPORTING the target of rejection, method of manufacture
for the particular casting-shall be finally recorded
4.1 Castings of repetitive nature in the weight in the method card.
range up to 500 kg shall be accounted for the
determination of rejection percentage on number 6.3 The Enal method card shall then be released
basis, that is, the number of castings inspected to all the concerned, that is, production, process
and the number of castings rejected. control, inspection and quality control depart-
ments.
4.2 Castings of jobbing nature shall be accounted
for the rejection percentage on weight basis. 7 REJECTION MEETING

5 REJECTION REPORTING SYSTEM 7.1 Depending on the production rate of the


foundry, a shop floor meeting shall be held daily
5.1 Daily Inspection Report or as required to examine the defective castings.

The report shall indicate casting-wise nurubers 7.2 The meeting shall be conducted by either the
inspected and rejected. The rejection shall be chief of quality control or trouble shooting unit
classified into different foundry defects and each who shall properly identify the defects decided on
casting of these groups shall be identified by the the unfinal status i.e. rejected castings, good
date of cast, serial nmber and shift when it has castings and repairable castings. The method of
been produced. rectification shall also be decided in the meeting.

1
IS 12880:1989

7.3 The meeting shall be attended by heads/ shall also be explained in simple language by
supervisors of all the production shops, process their supervisor about the result of trial.
control and quality control departments regularly.
Moulding shop group leader from the workmens 8.4 The master chart as in 5.3 shall be made use
side should also attend the meeting. of for the weekly rejection meeting.

7.4 At least once in a week, the foundry head 9 TRAINING OF PERSONNEL


shall meet his managers and supervisors to discuss
the rejection and to decide the lme of action. 9.1 Workmen, supervisors and managers shall be
required to undergo suitable technical and
8 FEEDBACK SYSTEM managerial courses to keep them up to date on
the subject. Such courses shall be either organized
8.1 Copies of rejection report shall be forwarded within the organization or by different educational/
to the foundry head who in turn shall pass them professional bodies.
on with his comments to the concerned
department. 10 SUGGESTION SCHEME

8.2 Display board indicating daily rejections on 10.1 Problems which are not getting solved easily
individual items produced and their break-ups shall be made upon for suggestion through proper
shall be kept on a place or places where the information system and the suggestion received
workmen and concerned supervisors shall see and shall be scrutinized on priority and actions shall
discuss among themselves for corrective actions. be taken accordingly.

8.3 Result achieved on any trial/action shall be 11 STATISTICAL QUALITY CONTROL


recorded in the form of report received from the
concerned department initiating the action and 11.1 For maintaining and analysing technical
copies be circulated among all concerned depart- date, suitable statistical methods, such as, control
merits. Workmen of the concerned department chart, etc, shall be utilized.

2
ANNEX A
[ Foteword ]

SCRAP DIAGNOSIS CHART FOR SOME COMMON DEtiCTS IN IRON CASTINGS,


THElR CAUSES AND REMEDIES

( For information only )

Defects Appearance Causes Remedies


Cold ShutlCoId Lap a) Hole in the thinner section rounding a) Low pouring temperature, slow or a) Adjust pouring temperature and
of edges with smooth and shiny - interrupted pouring use-ladle cover -
appearance
b) May appear as a line where two b) Low fluidity W Increase phosphorus, if permitted
forwarding fronts have not fused.
Casting surface closer to the defect c) Core shift causing uneven wall 4 Avoid core shift by proper print
may be smooth and shiny thickness or use chaplet wherever possible
d) Very hard mould or low 4 Avoid excess ramming
permeability
e) High moisture 4 Increase vents. Adjust moisture
as per sand GFN and clay
W
content
Cold Shut Gas hole having shiny surface with a) Turbulent flow of metal causing 4 Streamline and uninterrupted
embedded shot iron shots separating out of metal flow of metal is desirable
stream, interrupted pouring
Shrinkage and Draw Rough cavities entering casting on heavy a) Incorrect feeding a) Design correct gating and feeding
sections or at the joint of change of system
sections b) Weak mould b) Improve mould hardness/density
c) Carbon equivalent unsuitable for c) Select proper composition
the casting design
d) Excess inoculation d) Adjust inoculation suiting mel-
ting practice and casting design
e) High pouring temperature e) Reduce temperature wherever
possible

Shg Not so rough to smooth cavities a) Unclean metal/ladle a) Remove slag from the furnace
generally in the vicinity of gates prior to tapping into the ladle
Use coagulant for better removal
of slag from the ladle
b) Gating system unable to trap the b) Design gating system properly
slag
Defects Appearance Causes Remedies ?I
cr
c) Faulty pouring practice c) Keep pouring basin full during
pouring the casting :
0
d) Very high sulphur or manganese d) Use correct type of scrap and ..
ti
or both select proper composition to avoid
Mn-S slag g

Micro Porosity Machined surface shows localized See shrinkage and draw Same of shrinkage and draw further
spongy surface, may leak under
fluid pressure a) Core and mould having poor a) Avoid core/mould dilation
thermal stability
b) High phosphorus content b) Adjust suitable charge to avoid
phosphorus level

Chilled Edges and Bright areas oh the edges after a) Incorrect type of metal a) Adjust composition for correct
Hard Spot machining, fractured surface shows composition carbon equivalant percentage
white or mottled surface white shining
spots after machining b) Presence of excess carbide b) Avoid excess chromium, etc
stabilizing elements
c) Insufficient inoculation c) Use correct type and quantity of
inoculant
P
d) Sulphur not balanced with d) Balance sulphur with manganese
manganese I7 xS-I-03=Mn

Scab Rough sand/metal fused layer connected a) Expansion of silica not a) Balance clay/sand water propor-
to the casting by a thin strip of metal compensated by clay tions in the sand niix. Avoid
and on removril, may show a depression excess free water
on the casting surface
b) Erosion of the tiould surface in b) Increase clay, reduce water
front of the gates and its deposition Reduce metal velocity, as far as
in adjacent areas possible
c) Condensation of high moisture c) Samt as (b) and reduce pouring
layer in cope spetially flat surface time/temperature as far as
due to prolonged radiant heat practicable
Incorporate cellulose in the sand
mix
d) Inadequate combustible in sand mix d) Use adequate combustible

Distortion Casting shows swelling or growth oh a) Too soft a mould to withstand a) Ram evenly and firnily
surface ferrostatic pressure
b) Inadequate counterweight on the b) Increase weight . on mould/or
.
mould ensure proper clampmg
Warpage Casting shows warpage on cooling or a) High section sensitivity in iron a) Ensure correct inoculation
after machining
Rough Surface Casting surface rough a) Metal penetration a) Use finer sand or use coating, if
permitted
b) Insufficient coal dust to generate b) Use proper quality/quantity of
adequate lustrous carbon coal dust
4 Very hard mould surface c) Avoid hard ramming or adjust
the sand composition of suit
hard ramming condition
4 Base sand too coarse or distribution d) Select proper sand grading
too wide producing open grain
surface
4 Sand fusion e) Increase refractoriness in the mix
Reduce metal temperature if
possibIe
Crocks Hairline crack seen on casting surface a) High dry strength of the mould or a) Adjust ramming and clay content
and discolouration indicates crack poor collapsibility of the core Reduce oil, improve baking or
generation at high temperature use combustible filler material
otherwise it is cold crack
b) Improper handling b) Ensure propel handling
c) Incorrect loading during storage c) Avoid stacking of thinwalled
or transportation castings. Load flat castings
standing on the thicker section
d) Incorrect tool pressure during d) Use proper tool and clamping
machining during machining
Dirt Rough cavities and pits in casting surface a) Weak mould surface a) Ensure proper ramming
and before cleaning, sand grains may be
seen visually or under magnification b) Weak sand b) Maintain correct compression
strength of sand
c) Core print too tight c) Design proper prints
d) Pattern liner low d) Adjust liner hight to reduce
pressure at the drag/cope mould
cavity edges
e) Poor pattern finish or undercut e) Ensure proper pattern condition.
t;
f) Handling of moufds after closing f) Avoid manual handling of
closed mould a
g) Friable sand zo
g) Adjust moisture and clay content
of the sand mix ..
*
h) Optimize core baking z
\o
Defects Appearance Causes Remedies t;
Blow Holes CI
Smooth, nearly round shaped cavity a) Insufficient permeability of a) Avoid fines in the sand system c;)
may be on the surface or found after moulding or core sand 8
shot blasting or machining. Surface of ..
the cavity may be dull or shiny depending b) Hard ramming b) Avoid excess ramming t;:
on the nature of the gas causing the g
defect. In severe cases, section of the c) High moisture content of mould c) Minimize free water content in
casting may be hollow. the sand mix
d) Rusty or damp chills and d) Use coating in the chills and dry
chaplets them. Ensure chaplets are clean
and rust free
e) Very hard core e) Reduce organic binder content as
much as possible
f) Inadequate venting in the core and f) Vent sufficiently
mould
g) Underbaked core causing high gas g) Optimize baking/curing of core
content
h) Damp pouring ladle, spout and h) Ensure proper drying before
launder tapping of metal
j) Too low a pouring temperature j) Increase pouring temperature if
possible
Pin Holes Tiny subsurface round cavity normally a) High moisture in the sand a) Cut down source of hydrogen
having shiny surface. May be isolated associated with high aluminium which is normally water, optimize
or can be found in ciusters. Generally content of the metal quantity of inoculation. Control
found in the cope portion of the casting aluminium content of FeSi below
15 percent
b) High nitrogen content of the core b) Optimize use of nitrogen bearing
or mould binder and hardener
c) High manganese or sulphnr content c) Balance sulphur with manganese.
Control both to an optimum level

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