Defect Description Solution
Out of Air Cast

Insufficient air flow to suspend  the molten metal from contacting the graphite ring

 

Can have many causes but most common are due to:

  • –Airflow settings to low during cast start

  • Airflow adjustments made during a cast are too low
  • Graphite ring has poor uniformity and/or low total airflow
*

 

  • Use Mold Calibration System to insure correct airflow settings to each mold

  • Test molds using the  Casting Ring Testing System to insure rings have no dead spot in uniformity & sufficient total airflow for casting
–Shark Bite at Cast Start

Too much airflow causes metal to contact & momentarily hang up inside the mold

 
*Can have many causes but the most common are:

  • Too much airflow during cast start

  • Graphite ring has poor uniformity and/or high airflow

  • Poor mold coating near pocket of transition plate & graphite ring

 
  • –

    Use Mold Calibration System to insure correct airflow adjustments to each mold

  • Test molds using  Casting Ring Testing System  that shows any low or high flow locations in the uniformity of the ring
  • Operator training on proper mold coating procedures
 
 
*Vertical Drags

Metal icicles stick inside the mold causing metal to flow around contact point
*

Can have many causes but the most common are:

  • If defect repeats in same location:
  • *Graphite ring has poor uniformity
  • *Casing ring surface is damaged
  • If defect occurs randomly
  • *Poor mold coating in pocket of transition plate or deposits on casting surface
 
  • Use Mold Calibration System to insure correct airflow adjustments to each mold
  • Test molds using Casting Ring Testing System  that insures graphite rings have no dead spot uniformity & sufficient total airflow
  • Operator training on proper mold coating procedures
 
 
*

Horizontal Tearing

Same as Out of Air Cast where metal contacts the graphite ring but under hotter casting conditions.  

*

Can have many causes but the most common are:

  • Airflow settings too low during cast start
  • Airflow adjustment made during a cast are too low
  • Graphite ring has poor uniformity and/or too low of total airflow
 
  • Use Mold Calibration System to insure correct airflow adjustments to each mold
  • Test molds using Casting Ring Testing System  that insures graphite rings have no dead spot uniformity & sufficient total airflow
 
 
*

Bleed Out during Steady State

Same as Out of Air Cast where metal contacts the graphite ring but under much hotter casting conditions.  

*

Can have many causes but most common is due to:

  • Airflow settings too low during cast start
  • Airflow adjustment made during a cast are too low
  • Graphite ring has poor uniformity and/or too low of total airflow
 
  • Use Mold Calibration System to insure correct airflow adjustments to each mold
  • Test molds using Casting Ring Testing System that insures graphite rings have no dead spot uniformity & sufficient total airflow
 
 

For more detail troubleshooting contact RJ Collins Incorporated.

 

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