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Note Steel chills stay in the casting permanently unless they happen to be sited in areas that are subsequently machined. Their permanent existence in iron castings does not cause any weakness, although with steel castings any chills used must, of course, have at least as good metallurgical properties as that of the metal being cast. Porosity and sponginess Casting porosity, usually affecting heavy, thick sections. Causes Incorrect metal composition such as too much phosphorus; too few risers or risers not large enough or incorrectly placed to allow them to feed the casting adequately with molten metal during solidification; slag inclusions in the metal.

Technology and competitiveness—steelmaking and casting. Teesside: Teeside Laboratories. Council of Ironfoundry Associations 1970. A practical guide to the design of grey iron castings for engineering purposes. London: CIA. Wysk 1989. Modern manufacturing process engineering. New York: McGraw-Hill. Strowbridge 1981. Low-pressure diecasting. Engineering, 221, 1–8. Reynolds, T. 1993. Continuous casting machine design. IGDS course in metals technology management— continuous casting module. Sheffield University, December 1993.

Causes Too rapid cooling in localized areas, usually in thin sections; incorrect use of chills 19 SHAPES MADE FROM MOLTEN METALS—CASTING (small pieces of steel built into selected points of the mould to speed up cooling in localized areas, and thus even out cooling across the whole casting). Note Steel chills stay in the casting permanently unless they happen to be sited in areas that are subsequently machined. Their permanent existence in iron castings does not cause any weakness, although with steel castings any chills used must, of course, have at least as good metallurgical properties as that of the metal being cast.