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Aluminium Casting Defects

Explore the common aluminium casting defects & identifying solutions in the Casting Defects Handbook. Uncover defects & prevention strategies for cold laps, cold shuts, laminations & more.

In the book “Casting Defects Handbook: Aluminum & Aluminum Alloys”
by David Neff








Many of the common types of aluminium casting defects encountered in the production of aluminum alloy castings are presented. These defects are categorized by production method:

  • sand-casting
  • permanent mold
  • high pressure diecasting
  • low pressure
  • investment
  • plaster and lost foam.

Possible causes of aluminium casting defects are indicated  and, in some cases, prevention techniques listed.

Suitable for foundry floor operators, as well as process engineers, metallurgists and quality control personnel.

Provides a comprehensive visual atlas of the more common casting defects encountered by aluminum foundry personnel, and provides a tool for quick identification.

Can be used to address possible causes and to establish corrective actions.


Chapter 1 : Sand Casting
Chapter 2 : Permanent Mold
Chapter 3 : High Pressure Diecasting

Diecasting—Process Related (DCP) Defects

  • Cold Laps
  • Cold Shuts
  • Laminations
  • Flow Marks
  • Knit Lines
  • Scratches
  • Sinks
  • Die Soldering
  • Hot Tearing
  • Shrinkage Porosity
  • Misruns
  • Lubricant Stain

Diecasting—Metallurgical-Related (DCM) Defects

  • Gas Porosity (Also Includes Air Entrapment which is Process-Related)
  • Inclusions, (Oxides, Corundum, Refractory, Flux)
  • Blisters
  • Leakers

Chapter 4 : Low Pressure Casting
Chapter 5 : Investment Casting
Chapter 6 : Plaster Casting
Chapter 7 : Lost Foam Casting

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