Advanced Techniques in Casting Defects and Rejection Analysis: A Study in an Industry

Casting process is the most widely used process in manufacturing industries especially in automotive products. Production of casting involves various processes like pattern making, molding, and core making and melting. It is very difficult to produce defect free castings. A defect may be the result of a single cause or a combination of causes. The castings may have one or more defects. Foundries are still using trial and error methods to solve quality problems. There are benefits of using a more disciplined approach to define, identify and determine the root cause of the defect which is an expensive and error-prone process. This project is about new devolvement for identification of defects for 4R cylinder block which is presently having a 40% or more percent rejection in Kirloskar ferrous industrial ltd, Solapur