MCD Engineering Group
Casting defect analysis articles focused on identifying root causes of defects in aluminum and ferrous castings. Topics include oxide entrainment, bifilm defects, porosity, inclusions, shrinkage mechanisms, turbulence-related damage, metallurgical quality, melt handling and process stability. These technical articles examine real-world casting failures, manufacturing issues and process-driven approaches to defect reduction and quality improvement.
Casting simulation is deterministic. If the geometry, material properties, and boundary conditions are unchanged, the simulation will always predict the same result. The fill pattern will be the same. The solidification path will be the same. The last-to-freeze location will be the same. The predicted shrinkage will be in the same place every time. Yet … Read more
Introduction Casting is one of the oldest and most versatile manufacturing processes, but it comes with a challenge every foundry engineer knows well: defects. From surface blemishes to hidden internal flaws, defects reduce yield, increase scrap, and can compromise safety if undetected. What often gets overlooked is this: it’s not enough to just notice a defect … Read more