Cast Iron and Cast Steel Castings Quality Control,
Material, Visual, Defects and Dimensional Examination
As for cast iron and
cast steel parts, quality issues are always very important. The
following will elaborate our experience to the quality control,
ex-work inspection, material, visual, defects and dimensional
examination. Also we will introduce standard inspection reports and
certificates our Dandong foundry used.
Why the quality control is important
for metal castings?
The production for metal castings is a very complex process. There
are many processes involved, such as gating design, raw material
control, melting, pouring, sand control, molding, cleaning,
grinding, machining etc. Therefore, any mistakes and unstable
factors will cause some problems and defects. So, the quality
control is a very important mission for both producers and buyers.
buyer need to consider the quality control issues?
Some buyers may think the quality control is the responsibility of
foundries, but I think this is not correct.
The buyers will know the key quality points better than foundries,
so without the support and requirements from the buyers or final
clients, the foundries will misunderstand the quality requirements,
overlook the key points, or doing some useless inspection.
Therefore, the buyers should try the best to involve the quality
control as far as they could. Once if the compensation occurs, the
loss will be the money, market, reputation.
the Chinese metal foundries control the casting quality?
As for the casting manufacturer, the metal foundries, they should
control the quality from the following aspects:
1. Raw material control, including pig iron purchasing, steel scrap,
alloy agents, sand materials and all other materials.
2. Sand molding control, this is inside control to molding workers.
3. Melting and pouring control, including the temperature and
4. Visual inspection to the surface qualities.
5. Dimensional examination to the before and after machining.
6. Chemical examination to the main chemical components, such as C,
Si, Mn, S, P etc.
7. Mechanical examination to the tensile strength, yield strength,
elongation, hardness etc.
8. Metallographic examination to the micro-structure and nodular
9. Some special inspection, such as UT test, Impact test, hydraulic
pressure test, coating thickness etc.
ex-work inspection for metal castings?
Before delivery, the metal foundry should focus on the following
1. The material reports, needed and qualified?
2. The dimensional and visual reports, needed and qualified?
3. The main quality issues, problems, solved or not?
material inspection report, certificate?
The following is a sample of material inspection report from Dandong
Foundry, you could see its main content including chemical
composition, and mechanical inspection results.
sample of material inspection report of pdf version.
dimensional and visual inspection report, certificate?
The following is a sample of dimensional and visual report from
Dandong Foundry. We combined the dimensional and visual inspection
results in one report, which will be better for both inspectors and
The sample of dimensional and visual inspection result of pdf
inspect the main quality issues and problems?
We made one document for each casting part. This document will
elaborate the main quality problems occurred before, and all key
quality points. This document will be updated step by step with the
improvement of the casting parts. So, before delivery, the inspector
will see this document, and will check if these problems have been
inspect the casting defects?
The castings defects will include the surface defects and inside
defects. There are various defects for cast iron and cast steel
castings, for the photos of defects, please refer to our article “metal
Therefore, there are many different inspection methods for the
different defects. Most surface defects could be found by visual
inspection. As for the inside defects, the ultrasonic inspection is
effective. Other defects inspections include liquid penetration,
X-ray inspector, magnetic powder inspection etc.
There are also some destructive inspections when we make samples.
Although this method will scrap the castings, the result is more
accurate and evident.
Our Dandong Foundry is also using USA
Dakota Ultrasonic Velocity Inspector to inspect the material quality
by batches and the inside defects.