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10 Rules for Good Casting

The last few years have witnessed an unprecedented increase in our understanding of the casting process. Thus, as understanding has increased, the list of requirements has been steadily amended as they have become known. Starting from an initial list of four rules, 10 rules have now been identified that incorporate the latest technology for producing reliable castings. These are just the start. Additional rules may exist, but they remain to be further researched and clarified.

The 10 rules that follow are proposed as necessary, but not, of course, sufficient. They should be used in addition to existing conventional technical specifications such as alloy type, strength and traceability via ISO 9000, etc., and other conventional foundry controls such as casting temperature, etc.

Although not yet tested on all cast materials, there are fundamental reasons for believing that the rules have general validity, and are applicable for all types of metals and alloys, including those based on aluminum, zinc, magnesium, cast irons, steels, air- and vacuum-cast nickel, cobalt and titanium. Nevertheless, although all materials will probably benefit from the application of the rules, some will benefit almost out of recognition, whereas others will be less affected.

Listed in summary form, the rules are intended to assist the casting industry. Adhering to them will speed up the process of producing the casting right the first time, and should contribute greatly to reducing scrap when the casting goes into production. In this way, the casting industry will be able to raise standards without any significant increase in costs. Superior quality can be offered with confidence. Only in this way will castings be accepted by the engineering profession as reliable, engineered products, and assure the future prosperity of the casting industry and its customers.

Conversely, the rules constitute a draft process specification, which buyers of castings could demand if they wished to be assured that they were buying the best possible casting quality. If buyers specified that their casting sources followed such rules, the quality and reliability of the castings would be higher than could be achieved by any amount of expensive quality control on the finished product.

Next: Rule 1. Provide a Good Quality Melt >>

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