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Erosion scab

An erosion scab is an expansion defect in which the loosened sand has been eroded
away by the montion of metal, such as boiling and has left a solid junction between
the casting and defect. As such, the defect can be removed by cold chisel, usually
leaving a solid surface. However, it should be noted that the erosion scab result in
sand holes or sand inclusions in some other part of the casting. Figure 8.1 shows a
typical erosion scab.
The erosion scab is similar in appearance to a cut or wash. It sometimes looks like a
rat-tail or drop. The cure, however, may be entirely different because an erosion
scab is essentially an expansion problem rather than a low strength (hot or dry)
problem. It is best understood by visualizing an expansion taking place in or on the
mold surface before the metal touches the surface at that point. Such expansion
loosens or weakens the mold surface to a predetermined depth.
When molten metal flow over such an expanded surface, it can readily cut or wash
the sand grains away, leaving a growth on the casting. As implied by the word
erosion, it is a cut, but the word scab implies that the cut or wash would not
occur if the sand had not tended to scab or buckle ahead of the metal flow.
Obviously, this defect is caused by the tendency of the sand to scab and of the
metal to erode or cut. Therefore, both metal flow and sand (or core) properties must
be evaluated.

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