Precision Casting Process Upgrade: Solving Porosity and Shrinkage Defects

Porosity and shrinkage are the most common internal defects in investment castings. They weaken structural compactness, mechanical strength and airtightness, easily causing part failure and high scrap rates for industrial equipment.To solve these key quality issues, we upgraded our full casting process. By adopting digital production and refined process control, we greatly suppress porosity and shrinkage, providing stable, high-performance custom castings for global customers.

Causes of Porosity & Shrinkage Defects

Porosity Defects: Caused by gas inclusion in molten steel, wet or impure raw materials, and insufficient shell drying or roasting. Moisture and organics in the shell generate gas during pouring, forming trapped internal or subcutaneous pores.Shrinkage Defects: Happen during solidification. Thick walls and hot spots shrink in volume. Poor riser design and insufficient feeding create tiny dispersed voids, lowering casting density and stability.

Core Process Optimization Solutions

1. Strict Melting ControlWe use high-purity raw materials and fully dry all accessories. Precise temperature control and real-time composition monitoring ensure full deoxidation and degassing, minimizing gas-related porosity.2. Accurate Shell Making & RoastingAutomatic constant temperature & humidity shell making ensures consistent shell quality. Complete high-temperature roasting removes moisture and residues, effectively reducing pouring gas generation.3. Mold & Solidification OptimizationWe apply casting simulation to predict hot spots and shrinkage risks. Optimized riser and chiller design realizes sequential solidification, ensuring sufficient feeding and eliminating shrinkage porosity.4. Standardized Pouring & Quality InspectionStable pouring parameters and optimized venting design ensure clean and smooth filling. Regular UT/MT non-destructive testing provides closed-loop quality control for stable batch quality.

Upgrade Advantages & Customer Value

After process upgrading, our casting qualification rate exceeds 98%. Lower defect and rework rates help customers reduce costs and shorten delivery cycles.We supply reliable carbon steel, alloy steel and stainless steel castings, including standard and complex custom parts. Our optimized process delivers high-density, long-service-life casting solutions for global industries.