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1、 1CASTING DEFECTS 铸件缺陷铸件缺陷 Casting defects may deter form the visual quality of the components causing rejections, More serious types of defect are those which increase local stresses or reduce the effective cross sectional area of the casting and thereby lower the mechanical properties. Internal de
2、fects of various types will cause reductions in fatigue properties and shock reistance. 铸件缺陷可能会阻止零组件的视觉质量并造成报废。较严重 的缺陷类型是指那些使局部应力增加或使铸件有效横断面面积减 少的缺陷，从而降低了机械性能。各种类型的内部缺陷将会导致 疲劳性能和抗冲击性能的下降。 Accurate identifions of defect type is necessary for rectification to be made to either the process or the input
3、 material quality. 在对工艺抑或输入材料的质量进行纠正的过程中，需要准确 地指明这些缺陷的类型。 DROSS AND INCLUSIONS 浮渣(熔渣)及杂质 Aluminium oxide or dross is formed at the molten metal/air interface. Dross may be removed by skimming the molten metal surface prior to dipping, tapping or decanting the metal. A flux may be used to recover mol
4、ten metal form the dross, chlorin injection will reduce suspended non-metallic par-ticles. 氧化铝或浮渣(熔渣)形成于熔融金属/空中接口。可在对金属 进行浸渍、出钢或倾析之前，采用撇除熔融金属/表面的方式，将 浮渣(熔渣)移除。 可能会采用溶剂来从浮渣(熔渣)中回收熔融金属 ，注入氯气将会降低悬浮的非金属颗粒。 Limiting the molten metal surface exposed to the air will reduce dross formation. To reduce dross
5、inclusions in castings, a turbulence free metal flow is required. Molten metal may be filtered to remove particles. 对暴露于空气中的熔融金属表面进行限制，将减少浮渣(熔渣) 的形成。为了减少铸件中的夹渣，需要采取无湍流金属流动。可2能会对熔融金属进行过滤以清除颗粒。 BLOWHOLES 气泡 Blowholes are that appear on the surface of a casting and are caused by not drying out the moul
6、d material or mould release agents sufficiently, prior to casting. 气泡是指出现在铸件表面的孔穴，它们是由于在铸造开始之 前，没有对浇注材料或脱模剂进行干燥所致的。 The presence of organic material in sand moulds may cause a local gas or steam generation when contacted by hot metal. 沙模中出现有机材料可能会产生局部气体或蒸汽(与熔融金属 接触时)。 SHRINKAGE POROSITY 收缩孔隙度 Shrink
7、age porosity on a casting surface is due to poor feeding, uncontrolled solidification or poor metal fluidity which causes metal to shrink away from the mould surface. This may be rectified by a change in the feeding arrangement, or the location of chills or a change of alloy. With metal moulds, too
8、high a pouring temperature may cause this condition. 铸件表面上的收缩孔隙度是由于送料不良、未受控凝固、或 金属流动性不良所致，它使金属从模具表面退缩。对于这一点， 可以通过改变给料布置或激冷位置或改变合金，进行纠正。采用 金属铸型，过高的浇注温度可能会导致这种情况的发生。 Interior shrinkage porosity is not easily seen as the exterior appearance of a casting may be sound, but the interior could suffer form
9、excessive porosity, which is caused by poor feeding. 在铸件的外观完好的情况下，则不易看到内部收缩孔隙度， 但外部可能会遭受过分疏松，而这是由于给料不良所造成的。 SHRINKAGE CRACKS 3缩裂 Shrinkage cracks are most common at corners, at fillets and areas of large change in section, where the metal shrinks away from the surface giving an appearance of a crack
10、. The provision of chills for controlling solidification, redesigning angles to avoid stresses and altering feeding arrangements will minimise shrinkage cracks. 缩裂在角、倒圆角以及在区段中存在较大变化的区域中最为 常见，在这些地方金属从表面退缩，并在表面出现裂缝。提供用 于控制凝固的激冷金属、对角度进行重新设计以避免应力的出现 ，以及更改给料安排，都将使缩裂得程度降至最低。 MICROPOSITY/GAS POROSITY/PINHO
11、LES 微孔率/气孔隙度/针孔 Gas dissolved in the molten metal may lead to fine round voids in the solidified casting. Gas porosity may be controlled by degassing the metal prior to pouring and improving the feeding arrangements to avoid excessive turbulence, and by ensuring adequate permeability in sand moulds.
12、 溶解于熔融金属中的气体可能导致在凝固了的铸件中出现细 微的圆形孔穴。可通过在浇注之前对金属进行除气、改进给料配 置以避免出现过度湍流、以及在沙模中确保充分渗透性的方式， 对气孔进行控制。 A fine grain size ensures more finely dispersed pores, whereas a coarse geain size lead to larger pores at grain boundaries. 细微的晶粒度可确保获得更为精细的分散孔，而粗糙的晶粒 度则会在晶界产生较大的孔隙。 Internal pores may link up to allow ga
13、s or liquid to leak through the castings thus reducing pressure tightness. 内部孔隙可以连接起来，使气体或液体渗透到铸件中，从而降 低气密性。 COLD SHUTS 冷隔 A cold shut is formed by metal that has fed from different directions meeting and not fusing together. Possible solutions are (i) increasing the pouring temperature and arrangin
14、g risers to allow venting of the mould to allow steam or air in the mould cavity to escape, giving free metal flow or (ii) choosing a more fluid alloy. 4冷隔的形成是由金属(其给料来自各个不同方向，而且彼此未 能聚集融合在一起)所致。可能的解决办法是：(i)提高浇注温度并 配置冒口，以使模具的排气口排除型腔中的蒸汽或空气，实现无 阻的金属流动或(ii)选择更为流畅的合金。 HOT CRACKING/HOT TEARING/HOT SHORTNE
15、SS 热裂/热拉裂/热脆性 Cracking on solidification is caused by tensile stresses building up in the metal as parts of the casting shrink on solidification. Higher silicon containing alloys are less prone to hot shortness. The use of chills at hot spots, to cause fast solidification at areas of large section,
16、and improverments to feeding in underfed sections are possible solutions. 在凝固出现的裂纹，其原因在于：随着铸件的某些部分在凝 固时收缩，在金属中出现了拉应力的聚集。合金中的硅含量较高 不太容易出现热脆性。可能的解决办法包括： 在过热点处使用激 冷金属，以达到在大区段区域实现快速凝固的目的，在供料不良 的区段，改善给料工况。 MISRUNS 滞流(浇铸不满) A misrun occurs when metal fails to fill the mould cavity; the incomplete casting would have to be scrapped. Low pouring remperatures, poor feeding, insufficient venting and dirty metal may have led to the met
