Slag related gas porosity in grey iron often occur as rounded or irregular shaped cavities either inside the casting or open to the surface. Typically, clusters of slag or dross are found in conjunction to the cavities. The blowhole itself is a result from gas formation (typi- cally CO gas evolution), from reactions between the slag and the carbon content in the iron.
Example of surface slag blowhole in grey iron. Close-up of defect showing slag cluster.
Possible causes: Possible cures:
• Manganese sulphide or oxide separation • Use clean ladles and ensure that ladles aggravated by high sulphur and manga- are properly drained between fills. nese contents and low pouring tempera- • Reduce sulphur content to below 0.12%. ture. • Avoid excessive manganese content, • Improper slag separation. maximum 0.7%. • High sulphur content. • Improve slag skimming and removal • Slag contaminated ladles and improper procedures. draining leaving a cold metal heel in the • Increase pouring temperature. ladle that oxidized, causing Mn-oxide • Check gating system and secure that no formation. slag enters the mould, and avoid turbu- • High contents of Ca, Al or Ti. lent filling. • Use filters in the gating system.