A quick and easy-to-use guide intended for operator use on the shop floor. Contains casting photographs and photomicrographs for identification of 22 types of defects; provides brief descriptions and their causes; then guides the operator through a step-by-step series of process solutions to correct the defect.

TABLE OF CONTENTS

Introduction
An overview of the Troubleshooting Guide
Chapter 1:  Basic Procedures for Controlling Defects
Some of the major operational practices required to reduce or eliminate defects
Chapter 2:  Surface Defects
Those commonly known as cold Flows or Non-Fills
Chapter 3:  Laminations
Defects from layers of metal forming during the processes
Chapter 4:  Gas Porosity
Internal porosity resulting from trapped gases of various kinds
Chapter 5:  Blisters
Surface manifestation of trapped gases
Chapter 6:  Flow Porosity
Surface or internal porosity arising from poor pressure conditions
Chapter 7:  Shrink Porosity
Porosity from volume changes as the metal changes state
Chapter 8:  Heat Sinks
Surface depressions resulting from shrinkage porosity
Chapter 9:  Leakers
Porous sections of the casting
Chapter 10:  Cracks
Both visible and not-very-visible cracks in the casting
Chapter 11:  Inclusions
Foreign material that may cause machining problems
Chapter 12: Solder
Buildup of cast material on the die, causing damage to the casting surface
Chapter 13:  Carbon Buildup
Deposits other than cast material on the die, causing damage to the casting surface
Chapter 14:  Erosion, Caviation
Removal of die steel with subsequent deformation of the casting
Chapter 15:  Outgassing
Gas escaping from the casting during painting or finishing operations, causing defective surface finish
Chapter 16:  Edge Porosity
Porosity at the gates
Chapter 17:  Bending, Warping
Deformation of the casting sometime after its formation in the die cavity
Chapter 18:  Flash
Excessive cast material extending from a parting line, often accompanied by dimensional deviation
Chapter 19:  Stained Castings
Discolored castings
Chapter 20:  Waves and Lakes
Decorative castings with small imperfections visible only under reflective light
Chapter 21:  Drags
Surface area of the casting is broken by metal stuck to the die
Chapter 22:  Deformation From Ejector Pins
Casting is deformed by ejector pins
Chapter 23:  Excessive Flux
Excessive corrosion or porosity from excessive flux