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Incomplete fusion is also known as overspatter. It is caused when the molten metal is confined in the mould such that the interface is overheated, and welding is not successful. If incomplete fusion occurs, it can be a random, microscopic defect, or it can be an area of missing fusion, known as root tearing.
Incomplete fusion occurs when the mould used for casting is not designed for the process and the flow of the molten metal is not as designed. This can result in reduced flow in the mould and poor fusion in the cast. It can also cause the base metal to remain in the mould and not flow away. In most cases, this type of incomplete fusion is caused by poor mould design.
Incomplete fusion can also be caused by the stresses induced in the molten metal during welding or by the weld process. These stresses can result in incomplete fusion. In some cases, the weld metal is fused with the base metal but the base metal is not welded to itself. The base metal may also not be fully molten around the weld metal in some types of welding.
A cross-sectional defect is caused when the mould is cast incorrectly. The lack of fusion can be because of the mould design, the materials used, the use of improper filler metal, or an improper casting process. The most common cross-sectional defect is the lack of fusion. A process-induced cross-section defect is caused by the internal stresses in the casting when they exceed the casting's yield point. These defects appear on the root face of the casting.
Common defects include dross, cold tears, cold cracking, and shrinkage porosity. Dross is a common surface defect, and its formation is often unavoidable. The other defects, however, can be prevented by proper casting procedures and through the use of proper equipment. Dross and other defects should be examined regularly during the casting process, and eliminated if necessary. Heat-affected zones and other internal defects can also be present in castings. Heat-affected zones occur when the cast metal is heated during the casting process. This causes some of the casting to be changed chemically or mechanically, and may cause changes in the surface topography of the casting. Internal defects can be present in any part of a casting. They are often caused by improper casting procedures, and are most common when the casting is the product of a rapid manufacturing process. Finally, the casting should be inspected for surface defects. If the casting has any surface defects, they should be removed. If any defects are present, they should be eliminated.
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