Template: troubleshooting sheet for casting defects
Document error type, probable cause and corrective action
When a piece is scrapped or marked as defective, it's valuable to document the defect systematically—not just for that one piece, but to be able to fix the underlying cause in production. Use the template below as a starting point.
§Basic information
- 01Part/order number and casting date
- 02Material/alloy (e.g. GJL GJS steel)
- 03Where in the process was the error discovered (visual inspection, NDT, machining)?
| Error type | Typical characteristic | Probable cause | Corrective action |
|---|---|---|---|
| Gas porosity / voids | Small/large voids in the material | Moisture in sand/core, air in the melt | Dry mold and core better, check degassing |
| Cold joint | Weak Line Where Metal Has Not Fused Together | The metal is too cold at the confluence, poor inlet design | Adjust temperature/pour speed or inlet |
| Indicator | Foreign body or slag in the material | Impurities from smelting or mold. | Better slag separation, check mould cleanliness |
| Andet/note | Describe the error in your own words | Specify assumption | Specify proposed action |
§Follow-up
- 01Is the error isolated or have several identical errors been seen on the same order?
- 02Is there a need to adjust a work procedure or core recipe permanently?
- 03Has the error been shared with relevant colleagues so the same error is not repeated?