Casting defects resulting from mould and core sands used in foundry and their preventation

In this study, common casting defects in the green sand moulding process with cores produced from amine gas hardened sand and cold box method, which are widely used in the industry for the lowest cost production of high-volume casting parts, were investigated. Defects are explained with real examples with their formation mechanisms, classified according to AFS coding and handled with solution methods. While searching for solution methods, versatile technical problem solving technics and advanced engineering tools such as fishbone and casting simulation program were used. The unavoidable part of sand-induced casting errors, which can be prevented up to a certain level with strict process control tests, can be triggered by other inputs and variability of the process. Looking at the problem from the process window is a necessity for a solution in a production process where there are many variables such as casting. In the examples described in the case study section, the effect of casting method components that cause extra heat input in the molding sand and the mold cavity filling profile on the dart failure was determined using casting simulation.