The goal of this project is to develop a model to help foundries learn the mechanisms of porosity formation and other effects of gases in their iron castings. It will establish a quantitative relationship among the factors affecting porosity formation and better enable foundry operator to reduce/eliminate porosity formation in a production environment.
For most foundries, porosity problems occur sporadically, but even occasional outbreaks can be costly. Even a small amount of porosity can significantly reduce the mechanical properties of the castings; as a result, the casting will have to be scrapped. In general, ½ to ¾ of the all-scrap castings are lost to factors related, directly or indirectly, to porosity. Despite the obvious importance of the problem, there is no consensus on how to deal with it.
Most porosity in iron castings is believed to be a result of the combination of solidification shrinkage and a decrease in the solubility of gases during solidification. Unfortunately, there are insufficient data to support this theory. Therefore, it is essential for the foundries to learn the mechanisms of porosity formation and other effects of gases in their iron castings. It is also essential to establish a quantitative relationship among the factors affecting porosity formation, in a form that can be used to predict its formation in a production environment.