Rejection Rate Minimization of Cast Iron
Components Through Metallurgical
Analysis
K. Santhy and D. R. Rajkumar
Abstract Many small-scale industries are producing various components by sand
casting method. The rejection rate of these components is reasonably high which can
reduce by proper failure analysis. The current work involved detailed investigation
on rejections, and its causes of ductile and grey cast iron components such as harvest
cup, chain link, and non-return valve in an industry. Initially, the major defects which
cause the significant rejection of the products are identified by visual inspection. First
analyses were carried out to understand the causes for the defects by permeability
test, moisture determination test, grain fineness test, swelling index of bentonite
test, green compression strength test, loss of ignition test, mould hardness test and
refractoriness test for sand and mould; secondly, chemical composition was analysed
before and after inoculation addition by spectroscopy test. It helps to identify if
the carbon equivalent falls in the required range or not. Thirdly, microstructure of
the material was studied before and after etching by employing optical microscopy
test and phase analysis by XRD. In addition, the mechanical properties of the cast
materials were studied using UTM and fractography study with the help of SEM.
Based on the consideration of test results, procedures adapted in the casting process
and environment condition, suitable corrective actions are recommended to reduce
the rejection rate of the components.
Keywords Defect analysis · Ductile and grey cast iron · Sand and mould test ·
Microstructure · Materials characterization · Mechanical testing
K. Santhy (B)
Department of Materials and Metallurgical Engineering, Indus Institute of Technology and
Engineering, Indus University, Ahmedabad 382115, India
e-mail: k_santhy@rediffmail.com
D. R. Rajkumar
Department of Mechanical Engineering, CARE Group of Institutions, Tiruchirappalli 620009,
India
© The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2021
A. K. Parwani et al. (eds.), Recent Advances in Mechanical Infrastructure,
Lecture Notes in Intelligent Transportation and Infrastructure,
https://doi.org/10.1007/978-981-33-4176-0_5
55
Components Through Metallurgical
Analysis
K. Santhy and D. R. Rajkumar
Abstract Many small-scale industries are producing various components by sand
casting method. The rejection rate of these components is reasonably high which can
reduce by proper failure analysis. The current work involved detailed investigation
on rejections, and its causes of ductile and grey cast iron components such as harvest
cup, chain link, and non-return valve in an industry. Initially, the major defects which
cause the significant rejection of the products are identified by visual inspection. First
analyses were carried out to understand the causes for the defects by permeability
test, moisture determination test, grain fineness test, swelling index of bentonite
test, green compression strength test, loss of ignition test, mould hardness test and
refractoriness test for sand and mould; secondly, chemical composition was analysed
before and after inoculation addition by spectroscopy test. It helps to identify if
the carbon equivalent falls in the required range or not. Thirdly, microstructure of
the material was studied before and after etching by employing optical microscopy
test and phase analysis by XRD. In addition, the mechanical properties of the cast
materials were studied using UTM and fractography study with the help of SEM.
Based on the consideration of test results, procedures adapted in the casting process
and environment condition, suitable corrective actions are recommended to reduce
the rejection rate of the components.
Keywords Defect analysis · Ductile and grey cast iron · Sand and mould test ·
Microstructure · Materials characterization · Mechanical testing
K. Santhy (B)
Department of Materials and Metallurgical Engineering, Indus Institute of Technology and
Engineering, Indus University, Ahmedabad 382115, India
e-mail: k_santhy@rediffmail.com
D. R. Rajkumar
Department of Mechanical Engineering, CARE Group of Institutions, Tiruchirappalli 620009,
India
© The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2021
A. K. Parwani et al. (eds.), Recent Advances in Mechanical Infrastructure,
Lecture Notes in Intelligent Transportation and Infrastructure,
https://doi.org/10.1007/978-981-33-4176-0_5
55