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Foundry piece defect repair
Complex shapes and sizes of metal objects, such as auto parts, equipment and tools, are formed by a manufacturing process known as foundry casting. During the casting process, metal heated to a liquid state is poured into a mould to create the desired product. However, casting products often have surface defects or internal defects, such as cracks, gas holes, sand holes, poor surface finish, etc.
Foundry defect repair is a process used to fix these surface and internal defects. To prepare the casting for repair, the casting surface must be cleaned properly, thereby eliminating any dust, dirt, oil and other contaminants. The affected area is then heated to a certain temperature. This is followed by grinding and sanding the surface to remove any sharp edges and surface imperfections. The heated area is then filled with a heat-resistant material, such as a welding rod or ceramic material, where the material is typically chosen based on the composition of the casting, as well as the temperature of the affected area.
After the material is filled and welded with a foundry welder, the repaired area is examined for stress or voids. If voids, cracks or other inconsistencies are noticed, the process must be repeated, either by heating the casting, filling the voids with a welding rod or ceramic material and repeating the welding process. Once the entire process is completed, the casting is examined again for any indications of surface or internal defects.
Foundry defect repair is a complex process that requires expert knowledge of welding and foundry casting, as well as a mastery of temperature regulation. As a result, it is highly recommended that only professional welders and cast makers perform the process. When done properly, this process can help restore the original properties of the metal and ensure the casting is free of any defects.
