Casting defects

problem

cause

precaution

Distorted casting

Distorted wax pattern

Proper manipulation of
wax & handling of
pattern.

Setting & hygroscopic

expansion of
investment
Poor surface finish
-fins / spines
-nodules

-flaking of the
investment when
mould is heated.
-Small air bubbles
attached to the
pattern.

-mold should be heated

gradually.
-vacuum investing
technique.
-vibration both before
and after mixing.
-proper application of
wetting agent.

-Veins & ridges

-rough surface

-water film formed

between investment &
wax pattern.
-too high/ low L:P ratio.
-prolonged heating of

-correct L:P ratio.

-proper application of
wetting agent.
-correct L:P ratio.
-accurate alloy
temperature.
-adequate casting

-localised
shrinkage porosity

-Shrinkage on
cooling of alloy

-microporosity
-mould/casting
temperature too
low.
Pin holes & gas
inclusion porosity

Occluded/trappe
d gases in
molten alloy.
-poorly adjusted
torch flame

Subsurface
porosity

Back pressure
porosity

-simultaneous
nucleation of
solid grains and
gas bubbles .
Trapped air
unable to escape
from mould

-Use correct sprue thickness

-Attach sprue at thick part of wax
pattern
-Use reservoir
-maintenance of appropriate
temperature.
Avoid overheating and prolonged
heating of alloy
-premelting the gold alloy on a
graphite crucible.
-correctly adjusting and positioning
the torch flame.
-controlling the rate at which the
molten metal enters the mold
Use porous investment
Avoid wax residue in mould
Place pattern 6 to 8 mm away from
end of ring
Use vents

Problem

Cause

Precaution

Incomplete
casting

-Improper venting of air. -Proper venting.

-Incomplete elimination -Proper handling
of wax residues.
of mould.
-Inclusion of foreign
bodies

black castingsurface
discoloration

-Incomplete wax
elimination
-prolonged mould
heating.
- High sulfur contents of
torch flame.

-accurate
temperature
maintaince.