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Casting and Machined Surface Finish Guide

This is the Example of PerfectStainlessSteelCasting Surface Finish that AlcoAutomation Pte Ltd will accept from thesuppliers.

The surface must be FREEof the

following problems:

1. Dents2. mperfections!. "asting lines#. $ne%enness&. Deep scratches'. (ould mar)s*. +ough surface,. (achine mar)s-. range /)in e0ect

The abo%e problems are

explained in the below pages.

And Alco will NOTaccept an

other form of unacceptable

surface nish tpes.

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Rough and Dirty

surface

Crack like line

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Orange Skineect

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Uneven surface

nish

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Uneven surface

nish

Mould Mark

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Dee!

Scratches

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Groove

surface

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Mould Mark

Mould Mark

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Marks on the

surface

Marks on the

surface

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+ough

surface

"rac) li)e

lines

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"#!erfection $

Groove surface

"#!erfection

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Dents and

!orosity #arks

Dee! dent

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1 INSPECTION STANDARD FOR EXTRUDED PARTS

Topic Description Preferred Accept Reject

Die Lines A longitudinal indentations or protrusions formedon the surface.

No Die Lines No more than 3 in a 25mm wide area higher ordeeper than 0.25 mm

Crack(ot !ear"

A crack occurs due to internal cooling stresses duringsolidification of low strength allo#s

No cracks A crack

$cratches%$pecs% nicks%gouges%

&arks in the e'trusion not designed to e there. No marks &arks not )isile afterfinishing process or has nodiscernale depth

Depth to mark isgreater than 0.25mm

$cuff marks A series of )er# light% concentrated scratches that cane seen ut not felt.

None None allowed on primar#sides% Allowale onsecondar# sides

$cuff marks on primar#side

2 INSPECTION STANDARD FOR MACHININ AND HAND!IN

Topic Description Preferred Accept Reject

*urred +dge &etal left around edge or drill hole% usuall# caused #machining or drilling

No urrs A urr that is dull orshorter than , mm

A urr that is sharp orlonger than , mm

Chipped&etal

$hown as nicks or it si-e metal remo)ed from thesurface due to tooling process. !#picall# chipped metalcan e found at edge or drill hole.

No chippedmetal

Chipped metal , mm indiameter on primar# side

/p to 3 chipped areas per25 cm2

(5 cm ' 5 cm" onsecondar# side

Chipped metal , mmin diameter on primar#side

&ore than 3 chippedareas per 25 cm2

(5 cm ' 5 cm" and ifcase metal is e'posed

Deformation A locali-ed mechanical induced defect that changes theshape of the metal. Classified under deformation aredents% nicks% gouges and scratches.

Nodeformation Does not affect form fit orfunction Affects form fit orfunction

1roo)ed$urface

1roo)es formed on the surface as a result of tool itcondition.

No surfacegroo)es

$lightl# groo)ed surface ea)il# groo)edsurface

idge A ridge remaining on the surface due to incompletelathing or remo)al of material

No ridges eight of ridge 0.25 mm ao)ereferenced surface

eight of ridge 0.25 mm ao)ereferenced surface

$harp orLoose &etal

$harp or loose metal can result during machining No sharp or loose metal $harp or loose metal

Deformed A deformation such that the ailit# to seal the unit will $mooth uniform mating $ealing of unit is

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sealing e compromised surfaces compromised

" INSPECTION STANDARD FOR CAST PRODUCTS

Topic Description Preferred Accept Reject

*lister Defect on the surface of a casting appearing as ashallow low with a thin film of metal o)er it

No lister A lister

*lowhole(*low"

Can appear as smoothwalled )oids or ca)ities% eitheron the surface or within a casting. *oth result fromgas or steam created during the casting process.

No lowhole A lowhole

Crack(ot !ear"

A crack occurs due to internal cooling stresses duringsolidification of low strength allo#s

No cracks A crack

4nclusions oreign material emedded in or on a casting.Common inclusions are o'ides% slag% and loose sand(t#pical for sandcasting".

No inclusions 4nclusions ,.5 mmdiameter

4nclusions ,.5 mmdiameter

&isruns (short

shots" andCold shots

A defect caused # improper filling of the ca)it# due to

cold metal% too thin a section or improper gating orpouring. A section of a casting which is not filled outis called a misrun or a short shot.!wo streams of metal not completel# fused is called acold shot.

No short shots

No cold shots

A short shots

A cold shot

6inhole6orosit#

7oids shown on the surface of the ase metal. !his isthe result of gas e)ol)ing through the metal.

No pin holes Diameter of a )oid is ,mm./p to 3 )oids per 25 cm2area (5cm ' 5cm"

Diameter of a )oid is ,mm.

&ore than 3 )oids per25 cm2area

(5 cm ' 5 cm"

Deformedsealing

A deformation such that the ailit# to seal the unit wille compromised

$mooth uniform matingsurfaces

$ealing of unit iscompromised