SAN:D TEI~JVIINO:LOGY

ARTIFICIAL

SAND: Product resulting Ji"0111

crushing a rock to the size of sand

grains, the fracture often passing tluough the component grains.

BANK SAND:

Sedimentary deposits, usually contail1ing less them 5% clay, oceun-ing

in banl\:8or pits, used in core making and synthetic molding sands.

BLENDED ~/10LDING SANDS: Naturally bonded molding sands which have

been mixed or modiJicd by the supplier to produce desirable properties.
BURNT SAND: Sand in wllich the binder or bond has been removed or impaired by
contact with mollcnmctaJ.

FACIN G SAND: Specially prepared molding sand mix hIre used in the mold adjacent
to the pattern to produce a smooth casting surface.

NATURA.L SAND: One derived from a rock, in \'ihidl the grains separate along their
natural boundaries. This includes unconsolidated sand, or a soft sandstone where little
pressure is required to separate the individual grains.

NATURALLY -BONDED J\10LDING SAND: A sand containing sufficient

bonding material as mined to be suitable for molding purposes.

SAND: A loose, granular material resulting from the disintegration of rock. The name
sand refers to the size of grain and not to mineral composition. Diameter of the individual
grains can vary from approximately 6 to 270 mesh. Most foundry sands are made up
principally of the mineral quartz (silica).

GATING SYSTElvI: The cOlllplete asselnbly of sprues, rulUlcrs, gates and individual
casting cavities in the mold.

SPRUE:

The vertical channel COIUlcctingthe pouring basin with the skimming gate, if
any, and the runner to the mold cavity, all of which together may be called the gate.

SPRUE: Sometimes used as a genetic tean to cover aU gates, risers, etc. returned to the
melting unit for re-melting.
RUNNER:

A channel through which molten metal or slag is pa.o;;sedfrom Olll.lreceptacle

to another; in a mold, the portion of the gate assembly that connect the downgate or sprue
with the casting ingate or riser.

GATE: End of the runner in a mold where the molten tnetal enters the casting or mold
cavity; sometimes npplied to the entire assembly of connected channels, to the pattern
parIs which fc.mn Ihem or

10

Ihe mclal whidl JiJls them, and sometimes

is reslricted

10

mean the first or main channel.

POURING BASIN: The enlarged mouth of the sprue into which the molten metal is
fIrst poured.

SKIM GATE: A gating arrangement which changes the direction of flow of molten
metal and prevents the passage of slag and other undesirable materials.
BOTTOl\rl RUNNING OR POURING:

Filling of the mold cavity from the

bottom by means of gates tram the runner.

CHOKE:

A restriction in the gating system for the purpose of keeping dirt" dross or slag
from entering the casting proper.

FINGER GA TE: Gate used on thin castings to allow rapid filling of mold. It is
wedge-shaped with thin edge divided vertically to produce several members or fmgers.
Metal flows into mold in several thin streams. Facilitates breaking gate tram a thin or
delicate casting.

HORl~ GATE: A semicircular gate to convey a molten metal over or under certain
parts of a castings that it will enter the mold at or near the center; also used as a skim gate.

SLOT GATE:

A gate used on vertical cylindrical castings in which the down sptue and
casting are connected over a large pal1 or all of the height of the casting.

PENCIL GATE: A series of small round gates entering the mold cavity iiom above
and coming from a common pouring basin.

GATE RING: A gate so fOlmed that a number of small gates conduct the metal fi'om a
circular tunnel' to a mold in the center.

GATE STRAINER:

A gate designed to prevent dirt and slag iiom entering the mold
and also to control the rate at which metal enter!'>the mold cavity.

SWHlL GATE:

1\ gale used wilh a feeder and runner designed 10 swirllhe

.metal in

the feeder to remove impurities.

POURING: Transfer of molten metal from furnace to ladle, ladle to ladle, or ladle into
molds.

RELIEF SPRUE:

In a mold a vertical channel, the approximate size of the

downsptue cormected to the tunnel' to relieve pressure surge during pouring. It functions
like a standpipe in a plumbing system.

RUNNER BOX: Device for distributing molten metal around a mold by dividing it
into several streams.

RUNNER EXTENSION: In a mold, that part of a runner which extends beyond the
farthest ingate as a blind end. It acts as a dirt trap since the fIrst rush of metal along the
runner will pick up any loose particles of sand or dirt and cany them into the extension
and not into the mold cavity.
RUNNER RISER:

A conventional runner, usually in the horizontal plane, which

permits flow of molten metal to the ingate and is large enough to act as a reservoir to feed
the casting.

SCREEN:

A perf()rated metal plate placed between the gate and nmuer of a casting
mold for the purpose of separating entrapped oxides, slag, etc., during the pouring.

SHOvVER GATE (PENCIL GATE, por

GATE):

In a mold, a gating system

by which metal sho"vers into the mold c:n,ity from a group of small gates at the top.

SKIlVI CORE (SKIlVll\r1ER): A 11atcore or tile placed in a mold to skim a flowing

stream of metal. Cormnonly used in pouring basins, it holds back slag and dirt willie clean
metal passes undemeath to the dovvnsprue.

SKIl\1 GATE:

A gating anangement which changes the direction offlow of molten

metal and prevents the passage of slag and other undesirable materials.

WHIRL GATE:

A gate and sprue ammgement which tangentially introduces molten

metal into a riser so the centrifugal action forces dirt or slag to the center of the liser and
away from the riser connection as the metal enlers the casting cavity.

SPRUE PLUG:

Wood or metal tapered roll or pin used to tonn a sprue opening, or .:l
metal plug left in the sprue after pow'ing has begun to allow filling or the poming basin
before the metal is allovved to enter the sprue.

LADLE: Metal receptacle frequently lined with refractors and used for transporting and
pouring molten metal. Types include hand, bull, crane, bottom-pour, holding, teapot,
trolley, shank, lip-pour, buggy, truck, mi'ting, reservoir.
LADLE, BOTTO~l

POUR: L'ldle from which metal, usually steel, flows through a

nozzle in the bottom.

LADLE, BULL: A large ladle for carrying molten metal. Frequently used to designate
a transfer ladle.

LADLE, CASTING:

A clllcible or iron vessel lined with refractory matelial for

conveying molten metal from the furnace and pouring it into the mold.

LADLE, TEAPOT: A ladle in which, by means of an external spout, iron is removed

from the bottom rather than the top.

TRr-\NSFI~RLADLE:

A ladle that may be supported 011 a monorail or carried in a

shank and used to transler metal hom the melting llJrnace 10 the holding furnace, or from
furnace to pouring ladles.

IUS:ER TEI~JVlINOLOGY
nOB: A riser or fceder, 118ua11y
hlind,

\0

provide molten metal to the casting during

solidification, thereby preventing sluinkage cavities.

BREAK-OFF CORE:

A thin core connecting the riser and casting which, while not
impeding the flow of metal, serws as a notch to assist in riser removal.

CHURN: Movement of mclall'Od up and

dO\VlI

ill

Ihe riser of a large casting Loprevent

iieezing over the top.

CORE BREAI(-OFF:

A core designed to produce a sharp break line in the gate for

ease of removal of feeder.

DIRECTIONAL SOLIDIFICATION: The solidiJication of molten metal in a

casting in such a manner that feed metal is always available for that pOliion that is just
solidifying.
D RA "V:

A tenn sometimes used to denote a shrink ;JppeaIing on the surface of a casting

or a rIser.

FEEDER, FEEDER HEAD:

A reservoir of molLen metal to compensate for the

contraction of metal as it solidifIes. J\tfoltcn metal flowing from the feed head, also known
as a RISER, prevents voids in the casting.

FEEDING: Pouring additional molten metal into a freshly poured mold to compensate
for volume shrinkage while the casting is solidifYing. Also the continuous supply of molten
meta~ as from a 1iser, to tile solidi{ying metal in a casting. Also refers to keeping risers
open by manipulation of feeding rods.
FEEDING ROD:

An iron rod used for keeping open the head or tiser, to which hot
metal is added from time to time as the casting contracts in cooling.

NECK DO\VN

(KNOCK-OFF, WASHBURN, or CAlvIERON CORE): A thin core

or tile used to restrict the riser neck, making it easier to break or cut off the riser from the
casting.

RISER:

A reservoir of molten metal provided to compensate for the internal contraction

of the casting as it solidifies.

RISER, BLIND:

A riser which docs nol break tlu'ough the top of the cope mold, and
is entirely sunoundecl by sand; often combined with ~pin gales, and together fanning an
effIcient method of gating and feeding a casting.

RISER-GATING:

Practice ofrun1l.ing metal for the casting tlu'ough the riser to help

drrcctionalsolidrlication.

RISER HEIGHT: The distance from the top of the riser when liquid to the top of the
riser neck. Riser height when solid may be several inches less than when liquid because of
loss of feed metal to the casting.
RISER NECK:

The cOlUleetingpassage between the tiser and the casting. Only the
height and width, or diameter, of the tiser neck usually are reported, although the shape
may be equally imp0l1ant.

RISER, OPEN:

Conventional i{)rlll of"riser usually located at the heaviest section of

the casting and extending through the entire height of the cope.

RISER PAD (RISER CONTACT):

An enlargement of the riser neck where it

joins the casting. The pUllJose of the pad is to prevent "breaking in" of the riser when it is
struck or eHtfrom the cHsting.

\VHIRL GATE:

A gate and sprue anangcmcnt which tangentially introduces molten

metal into a riser so the centrrlugal action forces diJ.1or slag to the center of the riser and
away from the riser cotillection as the metal enters the casting cavity.

MOLD/CORE l~ERMINOLOGY
ARBORS:

M.etal shapes embedded in and used to support either green or dry sand

cores.

BARS: Ribs of metal or wood placed across the cope portion of a flask. Sometimes
called "cleats". In some C:lses used <IS a drag to eliminate use of bottom boards.
BASE PLATE:

A plate to which the pattem assemblies are attached and to which a

flask is subsequently attached to fOlID the mold container.

BED-IN: Method whereby drag may be rammed in the pit or llask without necessity of
rolling over. Process used in production of heavy castings.

BOTTO~!fBOARD: A flat base of wood or metal for holding the flask in making
sand molds, or upon which the llask is placed on a conveyor.

BUILT-UP PLATE:

A pattem plate ofsnitabJc materiaL with the cope pattem

mounted on or altached 10 one side; the drag pattern may be altachcu to the othcr side or
to a separate mounting.

CAPTIVE FOUNDRY: A foundry that is an element of a manufacturing

establishment where foundry operations are a part of the regular operation of the plant.
CASTING (NOUN): Metal object cast to the desired shape by pouring or othelwise
injecting liquid metal into a mold, as distinct from one shaped by mechanical means.

CASTING, CENTIUFUGAL:
A process of 1illing malUs by 1) pouring the metal
into a sand or permanent mold that is revolving about either its horizontal or vertical axis;
or 2) pouring the metal into a mold that is subsequently revolvt":dbefore solidification of
the metal is complete.
CASTING, CONTINUOUS: A process in which the ingot is continually solidified
while it is being poure(~ and the length is 110tdetemrined by mold dimensions.

CASTING, PERl\!lANENT lVlOLD: A casting produced in a re-useable metal or

refractory mold.

CASTING, SAND:

1\ casting produced in a mold made of green sand, dried sand, or

a core sand.

CHAPLETS:

1\-1ctalsupports or spacers used in molds to maintain cores, or parts of

the mold which are not self-supporting in their proper positions during the casting process.

CHEEK: Intennediate section of a flask that is inserted between cope and drag to
decrease the ditficulty of molding unusual shapes or 10 fill a need for more than one
parting line

CHILL:

1) Addition of solid metal to molten metal in ladle to reduce temperature before

pouring; 2) depth to \vhich chilled structure penelrates a casting.

CHILL BLOCK.:

A cast iron test block in vvhich the depth of chill, as determined by

fracture, is used as :'Inestilnate of the cast iron's qU<llity.

CHILL COILS: (SPRliVG CI-IILLSj:

Chills made of steel wire formed into helical

coils or spirals.

CHILL NAIL: Special steel nails with heavy heads which [Ire placed in certain mold
sections to hasten solidification of the metal. Also used to support the sand facing against
which the metal will lie.
CHILLS:

Metal inserts in molds or ~res at the surface of a casting or within the mold
to hasten solidification of heavy sections and cause the casting to cool at a uniform rate.

CLEANER: A tool of thin steel or brass, 16 to 18in. long; one extremity has a bent
spatula blade, the other a short blade bent on the flat to a right angie. Used for smoothing
the molded surfaces and removing loose sand; also called a sleeker or sleek.

COPING OUT:

The exiension of sand of the cope downward into the drag, where it
takes an impression of the pattern.

CORE IRONS:

An irolJ, sleel bar, \vire, or other shape used within a core for
strengthening it in the green sand state to prevent distortion.

CORE JIG: A devise for setting core assemblies outside of the mold and placing the
'Vvholeassembly in the mold.

CORE l\1ARKER: A core seat so shaped or arranged that the core will register
conectly in the mold; also termed locator, indicator, register, tell-tale.

CORE PRINT: Projections attached

10

a pallern in ordcr to form recesses in the mold

at points where cores are to be supported.

CORE, RAlVI-UP 'VING: A core used to form a projection on a side of the casting.
The core print is wedge shaped and extends tu the pmting line.

CORES, LEFT AND RIGHT-HAND:

Cores made in separate whole boxes, alike

except that one has projection and bevel on opposite side.

CORE "'IRES OR ROnS: Reinrorcing wires or rods for fr:lgilc cores,

OOCH

prefOlmed into spedal shapes.

CRUSH STRIP OR BEAD: An indentation in the patting line of a pattern plate

which insures that cope and drag shall have good contact by producing a ridge of sand
which crushes against the other sutface of the mold or core.

CROSSBAR: Wood or metal bar placed in a flask to give greater anchorage to the
sand than is afforded by its four walls.
DAUBING:

Filling of cracks in molds or cores by specially prepared pastes or coatings

to prevent a mechanical penetration of metal into these cracks during pouring.

DIE CASTING:

A casting process by which the molten metal is forced under greater

than atmosphelic pressure into the metal mold cavity.

DOWEL: A pin of various types used in the parting surface ofpalted patterns or core
boxes to assure conect regularity.

l.b

DR.A",VPLATE:

A plate attached to a pattern to l~lci1itatedrawing of pattern lrDIu the

mold.

FLASK:

Metal or wood frame without top or fixed bottom used to hold the sand of
which a mold is formed; usually consists of two parts, cope and drag.

FLASK PIN: Guides to assure proper alignment of the cope and drag of the mold after
the pattem is withdravvll.

FLASK, TIGHT:

A type of flask which remains on the mold during pouring. Lugs

are normally provided for clamping cope and drag together for POUling.

FLOOR ~10LDER: Craftsman employed on the main foundry floor in making

molds for large castings generally from loose pattems.

FOLLO"V-BOARD:

A board which conforms to the form of the pattern and defmes

the parting surface of the drag.

FOUNDRY NAILS:

Coated steel nails with heavy heads, inserted in the mold wall to
hasten chilling action of the metal at that particular point, as well as to aid in holding the
sand-metal interface and prevent it from spalling; used to prevent cuts, washes, scabs at the
gate.

GA GG ERS: Metal pieces of inegular shape used to reinforce and supp0l1 sand in deep
pockets of molds.

GUIDE:

A ship or other suitable device used to locate the cope in the proper place on

the drag.

INGOT: A mass of metal cast to a convenient size and shape for re-melting or hot
working.

JO DB IN G FOUNDRY:

A foundry engaged in the manufacture of numerous types

of castings not intended for use in its own product. Usually refers to a foundry making
castings for many other companies.

1..1

LIFTERS:

Ivletal tool used for removing loose sand from cope or drag before closing
mold. Also, a device which is attached to the cope, to hold the sand together when the
cope is lifted.

LOOSE PIECE: 1) Core box; part of a core box ,,,hich remains embedded in the
core, and is removed after lifting off the core box. 2) Pattern; laterally-projecting part of a
pattem so attached that it remains in the mold until the hody of the pattern is withdrawn.
back-draft is avoided ,,,ith this means. 3) Part of a pcnrwncnl mold which remains on the
casting, and is removed ailer casting is ejected from the mold.

MASTER PATTERN:

A pattem embodying a contraction allo"vance in its

constmction, used for making castings to be employed as paltr.;rns in production work. In
investment casting, the object from which a die can be made, generally a metal mold of the
part to be cast, with process shrinkage added.

lVIOLD CAVITY: In a mold, the hole which, when filled ,,,-ithmetal becomes the
casting. Gates and risers are not considered pal1 of the mold cavity,.
lVIOLD 'V ASH: UsualJy an a<'iucousemulsion conlJining various compounds, such as
graphite, silica flour and the like, used to coat the face of the cavity in the casting mold.

lVIOLDWEIGHTS:

Weights placed on top of molds to offset internal or ferrostatic

pressure during pouring.

OPEN SAND CASTING: A casting which is produced in a mold which all poured
in the drag, and which has no cope or other top coveling.
PEELING:

Free removal of molding sand from casting upon shaking out from the

mold.

PERl\1ANENT lVIOLD:A metal mold of two or more pal1s that is used repeatedly
for the production of many castings of the same form. Liquid metal is poured in by
gravity. Not an ingot mold.
PIG BED:

Small excavations or regularly made open-sand molds on the foundry floor

to hold excess iron of the heat. May also demote a group of metal pig molds.

PILOT CASTING: A casting made fmm a production pattern to check accuracy of

dimensions and quality of castings which will be produced [rom that pattern.

12.

RAISINGS:

Sections of flasks, without bars, used together with flasks to give various
depths of flasks desired.

RIDDLE: A screening devll;e, manually or mechallil;ally operated, for removing coarse

particles and contamination from molding sand.
RIGGING:

Process of tooting pattem equipment for production-- as mounting pattems

on boards integrally vvith skimmers, gales, risl.:1's,ele.

RODDING:

Reinforcing the sand in a core with metal rods or shapes to strengthen

parts of the core.

ROLL-OVER

BOARD: A wood or metal plate on which the pattem is laid top face
downward for ramming the drag half of the mold, the plale and half mold being tumed
over together before the joint is made.
SAILORS:

An object hanging [ro.m a (Ope bar or other structural member and used to
support the sand.

SHOT AND GRIT: These two tenus refer to the metallic tY!leof abrasive commonly
used for cleaning castings. The shot is formed by blowing hut tHetal into a quenching tank
and subsequently screening into various sizes. The gIlt is produced by breaking up the shot
in either a ball or hanuner mill. A large percentage of the shot produced today is heat
treated to improve toughness.
SHRINKAGE:

Change in size as the metal passes from the fluid to the solid state in

the mold.

SLICK, SLICKER, Si\-100THER:

A tool used for mending and smoothing the

surface of a mold after withdrawal of pattern and before closing the mold.

STICKER:

A lump on the surface of a casting caused by a portion of the mold face

sticking to the pattem. Also, a fanning tool used in molding.

STOCK CORES: Cores of standard diameters usually made

011

a core machine and

kept on himd, sawed to required lengths.

STRESS RAISERS:

Factors such as sharp changes in contour or surface defects,

which concentrate stresses locally.

.13

8\V AD: A sponge or piece of waste, hemp, or other material used in dampening sand
around a pattem before withdrawing it. ~omctjmes use in blacking molds which might be
broken by a brush.
S\VEEP: A template cut to the profile of the desired mold shape, which when revolved
around a stake or spindle, produces that mold.
TIE PIECE: Bar or rod-shaped piece built into a pattern and made a part ofthe casting
to prevent distortion caused by uneven contraction between separated members.

TRYOFF: Procedure usually associated with mold assembly. It is a test for clearance,
bearing, and metal thickness. Performed by placing daubs of clay in position before
closing the mold.

TUCKING: Pressing sand with the fmgers under tlask bars, around gaggers, and other
places where the rmmner does not give the desired density.
VENT: A small opening or passage in a mold or core to facilitate escape of gases when
the mold is poured.

VENTING: Perforation with a venting wire of the sand over and around a mold cavity
to assist in the escape of the gases.

VENT \VlRE: A wire used to make vents or small holes in the mold to allow gas to
escape.

'VHISTLER:

A small vent opening from isolated mold cavities, usually high points, to
allow trapped gases to escape quickly.

HACK DRAFT: ;\ reverse lapel' which prevcllts removal of the pallem from the
mold.

BATTENS:

Wooden bars or strips fastened to bottom or follow board for rigidity or to

prevent distortion during ramming of the mold.

CENTER LINE:

Well defined gage-line placed on a geometric center of the work to

serve as a hasis from which dimensions are to be measured.

FINISH ALLO'VANCE:

Amount of stock left on the surface of a casting for

machine finish.

PARTING LINE: A line on a paLtem or casting corresponding to the separation

between the cope and drag portions of a sand mold.
PATTER.~: A foam of wood, metal, or other materials, around which molding material
is placed to make a mold for casting metals.

PATTERN BOARD:

Board having a tme sUIface upon which a pattem is placed

preparatory to making a mold of the paLLem.

PATTERJ.~ CHECI(ING:

Verifying dimensions of the paUem with those of the

drawing.

PATTERN COATING:

Materials applied to wood pattems to protect them against

moistme and abrasion of molding sand.

PATTERN DRAFT:

Taper allowed on vertical faces of a pattern to permit easy

withdrawal of pattem from the mold.

PATTE&~, GRAND ~ilASTER:

Pattem constructed with triple slrrinkage

allowance from which metal master pattetnc; are made.

PATTERN LAYOUT:

Full-size drawing of a pattem showing its alTangement and

structural features.

PATTERNMAK.ER' S SHRINKAGE:

Shrinkage allowance made on all patterns

to compensate for the change in dimensions as the solidified casting cools in the mold from
freezing temperature of the metal to room temperature. Pattem is made larger by the

nmount of shrinkage characteristic of the pmticular metal in the casting and the amount of
resulting contraction to be encountered. Rules or scales are available for use.

PATTERN1\;IAKIN G: SkilJed craft of modeling in wood, metal, or other materials

objects to be cast in metal.

PATTER1\T, lVIASTER:

Pattem constructed with double sluinkage allowance from

which production pattems are to be made.

PATTERN PLATES:

Straight flat metal or other plates on which patterns are

mounted.

PATTERN, TI~NIPORARY: A ptlttern used to produce a limited number of

castings and made as cheaply as the case will pelmit..
RAPPING: Knocking or janing the pattern to loosen it from the sand in the mold
before \vithdrawing the pattcm.
RAPPING BAR: :t\letal rod used to rap the draw spike to loosen the pattern in the
sand for drawing.

RAPPING P LATE: A metal plate attached to a pattern to prevent injury to the

pattern and assist in loosening it from the sand.
SHRINKAGE,

PATTERN~1AKER'S:

A scale divided in excess of standard

measurement to allow for the difference in size between the casting and the corresponding
mold cavity. Used by patternmakers to avoid calculations for shrinkage.

SKELETON P ATTERt~:

A framework or skeleton of ribs representing the interior

and exterior fmm and the metal thickness of the required casting.

STANDARD PATTERN:

A pattern of high-grade material and workmanship in

daily use or used at frequent intervals. A pattern used as a master to make or check
production patterns.

CASTING DEFECTS
BLEEDER: A defect wh~rein a casting lacks completeness due to molten metal
draining or leaking out of some part of the mold cavity after pouring has stopped.
BLISTER:

A shallow blow with a thin fum of metal over it appearing on the sUlface of

a casting.

BLOWHOLE:

Inegular shaped cavities with smooth walls produced in a casting when

gas, entrapped when the mold is being lilled, or evolved during solidification of the meta~
fails to escape and is held in pockets.

BUCKLE: An indentation in a castulg, resulting from expansion of the sand, may be

termed the start of an expansion defect.
BURNING-ON: Repailing a defective part of a casting by pouring fluid metal on it
until the defective part has become fluid, the whole masslhus fusing together. Should not
be confused with "burning-in."

CASTING STRAINS: Strains resulting from the cooling of a casting and sometimes
accompanied by residual stresses.
CENTERLINE SHRINKAGE:

Shrinkage or porosity occurring along the central

plane or axis of a cast pad.

COLD SHOT:

Small globule of metal embedded in but not entirely fused with the

casting.

COLD SHUT:

A casting defect caused by irnpelfect fusing of molten metal coming

together from opposite directions in a mold, or due to folding of the surface.

CONTRACTION CRACKS:

Cracks formed by the restriction of the metal while it

is contracting in the mold; may occur just after solidification (called a hot tear) or a short
time after the casting has been removed from the mold.

CORE BLOW:

A gas pocket in a casting adjacent to a cored cavity and caused by

entrapped gases from the core.

1.7

CORE RAISE:

A casting defect caused by 11otation of a core toward the cope surface

of a mold causing a variation in wall thickness.

CORE SHIFT:

A variation from specified dimensions of a cored section due to a

change in position of the core or misaligruncnt of cores in assembling.

CRACK, HOT TEAR:

A rupture in a casting OCCUlTing

at or just below the
solidifYing temperature by a pulling apart of the soft metal.

CRUSH: Buckling or breaking of a seclion of mold due

incorrect register when

closing. Also, an indentation in the casting sur1~lcedue to displacement of sand in the mold
when the mold was closed.
10

CUTS: Defects in a casting resulting from erosion of the sand by metal flowing over the
mold or core surface.

DRA'V: A tenll sometimes used to denote a shrink appearing on the surface of a casting
or rIser.

DROP: A mold defect caused by sand dropping from the cope or other overhanging
section, which results in a defect knmvn as a drop if the casting is poured.

EROSION SCAn:

A casting defect which occurs when the molten metal has been
agitated, boiled, or partially eroded the sand, in the mold, leaving a solid mass of sand and
metal at that point.

EXPANSION SCAB: Rough thin layer of metal partially separated from the body of
the casting by a thin layer of sand, and held in place by a thin vein of metal, usually
resulting in a thin indentation in the casting, caused by spalling of the mold face.
FIN: A thin projection of metal from the casting, formed as the result of imperfect mold
or core joints.

GAS HOLES:

Rounded cavities, either spherical, flattened, or elongated, in a casting,

caused by the generation and/or accumulation of gas or entrapped air during the
solidification of a casting.

HARD SPOTS: Dense inclusions in a casting, i.e., oxides, iron particles, sand, etc.
which are harder than the surrounding metal and cause machining difficulties.

Surface discontinuity or fracture caused by either extemalloads or

internal stresses or a combination of both acting on a casting during solidification, and
subsequent contraction at tt:lUpi..:raturesnear the solidus.

HOT TEAR:

INCLUSIONS:

Particles of impurities (usually oxides, sulphides, silicates and such)

that are held mechanically, or are fonned during solidification or by subsequent reaction
within the solid metal.

INTERNAL SHRINKAGE: 1\ void or network 0fvoids within a casting caused by

improper feeding of that section during solidilication.
lVIE'I'AL PENETRATION:

A casting sudace defect which appears as lithe metal

had filled the voids between the sand grains \vithout displacing them.

~IICROPOROSITY:
EXlremdy fine porosity caused in castings by slu"inkagc or gas
evolution and apparent on radiographic film as mottling.
IvnCROSHRINKAGE:
VelY finely divided porosity resulting from interdendritic
shrinkage resolved only by use of a microscope: may be visible on radiographic filins as
mottling ..
~IISRUN:

Casting not hIlly formed resulting from metal poured so cold that it solidified
before filling the mold completely.

MOLD SHIFT:

A casting defect which results when a mold does match at parting

lines.

OPEN GRAIN STRUCTURE:

A defect wherein a casting, when machined or

fractured, appears to be coarse grained and porous; usually due to a shrink area.

PINHOLE

POROSITY:

Very small holes scattered through a casting, possibly

caused by rnicroshrinkage or gas evolution during solidification.

PIPE:

A cavity fanned by contraction in metal during solidification, and occurring

where the last pOliion of liquid metal freezes, as in a riser.

POURED SHORT:

Casting which lacks completeness due to the mold not being

filled.

PULL DOWN:

A buckle in the cope, sometimes severe enough to cause a scab; also,

a shrinkage defect, as a draw.