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VDG SPECIFICATION

QUELLE: NOLIS (Norm vor Anwendung auf Aktualitt prfen!/Check standard for current issue prior to usage)
P 201
In case of discrepancies the German version shall govern.

Volume Deficits of Non-Ferrous Metal Castings


May 2002
The English translation is believed to be accurate.

Contents Page
1 Scope 2
1.1 General 2
1.2 Alloys 2
1.3 Casting processes 2
2 Explanatory notes 2
2.1 Porosity 2
2.1.1 Shrinkage cavities 2
2.1.2 Gas porosity 3
2.2 Other flaws 3
3 Possible effects of porosity 3
3.1 Static strength 3
3.2 Dynamic strength 4
3.3 General leak tightness and mating surfaces 4
3.4 Surface and heat treatment 4
4 Evaluation of casting porosity 4
5 Description of porosity 5
5.1 Pore classes 5
5.1.1 Pore class designation 5
5.1.2 Reference surfaces for the pore classes 6
5.1.3 Porosity class determination 7
5.1.4 Examples for pore class designations 7
5.2 Test options 8
5.2.1 Radiography test with image intensifier 8
5.2.2 Ultrasonic test 8
5.2.3 Leak tightness test 8
5.2.4 Visual test 9
5.2.5 Density test 9
5.2.6 Metallographic test and section test 9
6 Drawing notes 9
6.1 Collective notes 9
6.2 Notes for defined areas 9
7 References, standards, guidelines 10
Annex 1 Definition of further flaws 12
Annex 1.1 Cold flow marks 12
Annex 1.2 Build-up (stick marks) 12
Annex 1.3 Draw marks 12
Annex 1.4 Burrs 12
Annex 1.5 Hot cracks 12
Annex 1.6 Further characteristics of cast components 12
Annex 2 Microstructure examples of pore classes 0, 4 and 8 13
Annex 3 Examples of different porosity in general and in dependence on the
reference surfaces (informative) 14

Specification by the Special Technical Committees Die Casting and Light Metal Casting of the German
Foundrymens Association (VDG)

VEREIN DEUTSCHER GIESSEREIFACHLEUTE


To be obtained from VDG-Informationszentrum Giesserei, Postfach 10 51 44, D-40042 Dsseldorf, Telefon (02 11) 68 71-254
To be quoted only with permission of the German Foundrymens Association

Page 1, VDG Specification P 201 revised and updated 2002-10-16


1 Scope

1.1 General Fluid contraction

Specific volume, cm3/g


This VDG specification applies to non-ferrous
metal castings. It aims at a description of Solidification
casting quality requirements as well as their contraction

uniform presentation in technical


documentation. Solid contraction

TM
The scope of this specification is restricted to
inner and outer volume deficits (porosity).
Temperature, C
Other flaws such as sink marks, cold flow TM = Melting point
marks, build-up, draw marks, burrs and hot
cracks are not subject of this specification. Figure 1 Specific volume of aluminium
depending on temperature
Porosity can be minimised if designer and
caster collaborate. As generally outer shell and sprue of a part
solidify early, a volume deficit occurs in the
1.2 Alloys casting. This causes cavities in the casting. By
means of a suitable design of the casting, e.g.
The scope of this specification is restricted to avoidance of differences in the wall thickness,
aluminium, magnesium and zinc base alloy and optimum design of the casting system,
castings acc. to the relevant standards this volume deficit can be minimised.
(DIN EN 1706 "Aluminium, DIN EN 1753
"Magnesium, DIN EN 12844 "Zinc). Shrinkage cavities are hollow and have a
more or less rugged shape. In case the outer
1.3 Casting processes shell cannot withstand the stresses which
occur during shrinkage, this may result in
This VDG specification is restricted to die shrinkage cracks or hot cracks. If casting and
casting including related special casting mould are designed in an appropriate way,
processes, such as squeeze casting and these cracks and cavities can be cured by
thixocasting, as well as to sand casting and refeeding the affected areas. Alloys with a
ingot casting procedures. wide solidification interval are especially
sensitive to hot cracks.

2 Explanatory notes If cavities and pores can be observed with the


emmetropic eye, this is called
2.1 Porosity macroporosity, if not, it is called
2.1.1 Shrinkage cavities microporosity.

Shrinkage cavities result from the


2.1.2 Gas porosity
thermophysical properties of the cast
materials during solidification. It is impossible Gas pores can have:
to manufacture castings free of shrinkage
cavities. Thermodynamic causes
Fluidic causes
Metallic materials in liquid and solid aggregate
state have different densities and therefore
2.1.2.1 Thermodynamically caused gas
different specific volumes. The transition from porosity
liquid to solid state causes a change in
volume (Figure 1). For commonly used non- In liquid metals elementary gases generally
ferrous metal alloys, their volume decreases are better soluble than in solid metals.
during cooling (volume deficits, solidification Therefore gases are exuded during
contraction). solidification, which leads to pore formation.

Page 2, VDG Specification P 201


The pores accumulate in the area of
remaining solidification. In both cases points of force application,
stress intensity and areas of stress
In alloys with a distinct solidification interval, concentration should be given in order to
gas exudation preferably takes place between ensure suitable selection of pore classes.
the dendrite arms. As a result, gas pores
caused by exudation generally do not have a
3.1 Static strength
round contour. The contour rounding depends
on the gas content of the melt. When a force is applied to a component, this
causes stress in the cross section under load.
2.1.2.2 Gas porosity caused by fluidics This stress is proportional to the quotient of
force and cross sectional area. If the cross
During mould filling, gases are included as a
result of metal flow. These gases are either section is minimised (weakened) because of
gases from the ambient air or gases that pores, the stress increases. As soon as the
resulting stress exceeds the elastic limit of the
result from the thermal contact reaction
material, permanent deformation occurs which
between the melt and the moulding material or
can lead to fracture. In addition to this
the material of the casting mould and/or
increase in stress caused by the cross-
accessory casting materials such as release
agents, die lubricants etc. Gas pores caused sectional minimisation, a notch effect arises,
by fluidics generally are round as a result of depending on pore geometry. The most
critical aspect in the case of static stress is the
transitional stresses between gas and melt.
portion of pores related to the cross sectional
area and therefore the weakening of the cross
Note:
section .
In general, both types, shrinkage cavities and
gas pores occur in combination.
Under bending stress and torsional stress, the
position of porosity in relation to the neutral
2.2 Other flaws fibre is to be observed. Especially in the case
In addition to porosity other flaws may occur of shrinkage pores, porosity is located in the
which can influence the casting quality, such excess material area and therefore near the
as cold flow marks, built-up, draw marks, neutral fibre. As a result, strength reduction in
burrs and hot cracks. the total cross section is proportional to the
surface portion of porosity in good
These flaws are mentioned in this approximation.
specification and defined in Annex 1;
however they are not subject of this 3.2 Dynamic strength
specification. As far as possible, reference
Concerning the dynamic strength of a
is made to other guidelines and standards
component, besides the material the notch
that refer to these flaws and their test
effect is of great importance. Geometric
methods.
contours, inhomogeneity caused by oxide
films, inclusions, microstructure components,
intermetallic compounds etc., and casting
3 Possible effects of porosity defects can lead to notches having a more
serious effect than pores.
According to type and properties of the
component as well as to load case, pores in
Depending on their shape, their position
castings can affect strength, leak tightness
relative to the casting surface and their
under pressure, surface characteristics and/or
arrangement, pores have different notch
appearance of the component.
effects. The notch effect
In the case of technical grade components
Increases with the area occupied by
special attention shall be paid to the effects of
porosity and the pore diameter
porosity on component strength. The same
Decreases with better roundness and
porosity can have different effects on statically
greater distance of the pores from the
and dynamically stressed components.
casting surface

Page 3, VDG SpecificationP 201


Two types of porosity have to be
Examinations concerning the fatigue strength distinguished: macroporosity and
of aluminium cast alloys have revealed a microporosity:
decrease of the fatigue strength by approx. 15
to 20 % [1 to 11], when the porosity is Macroporosity includes all pores, the size
increased from pore class 0 to pore class 8 and shape of which can be specified with the
(see figure in Annex 2 [12]). emmetropic human eye or an auxiliary means
with the same resolution (such as X-ray
method). This applies to pores with a
3.3 General leak tightness and mating
minimum extension of 0.5 mm.
surfaces
When gas pores, shrinkage cavities and hot Microporosity includes all pores, the shape
cracks are directly connected with the casting and size of which cannot be reliably evaluated
skin (open pores, sink marks) or when they with the naked eye. This includes pores up to
are cut during machining, this may lead to a maximum diameter of 0.5 mm. The
leakage of the components or mating surfaces minimum pore size to be determined depends
depending on pore distribution. In connection on the resolution of the auxiliary means used.
with the requirement for leak tightness under
pressure, especially hot cracks and Porosity requirements shall be guided by the
interconnected cavities are to be considered component requirements (static strength,
as critical. fatigue strength, leak tightness under pressure
and function of machined surfaces,
Depending on their shape and size, pores can appearance of unfinished casting surfaces).
cause damage and/or impairment of seals. Evaluation criteria and measures shall be
defined by manufacturer and customer by
the time of ordering. Area-specific criteria
3.4 Surface and heat treatment should be explicitly defined on one component
If the components have been coated, (see 5.1). Publications [12 to 19] can help
electroplated or heat treated, surface porosity defining evaluation criteria and measures.
can cause points of discontinuity and/or
surface blisters. During heat treatment
(annealing, thermal drying of paints, etc.) of 5 Description of porosity
castings, the elevated temperature causes a
strength reduction of the material. As a result, 5.1 Pore classes
the internal pressure causes deformation
and/or blistering, especially of gas-filled pores. In order to describe all porosity requirements
This applies in particular to die cast of a component, different pore classes can be
components (see 2.1.2.2). Even in die casting, defined for sub-areas of the component.
blistering can be prevented to a great extent Experience shows that it is difficult to
by applying forced ventilation to the die. manufacture complex components in only
one pore class.

4 Evaluation of casting 5.1.1 Pore class designation


porosity The pore class designation consists of the
following parameters:
The degree of porosity depends on the
material, the manufacturing process, the Load case:
process-compatible design of the component, The load case parameter can be designated
its function and the permissible degree of as follows:
porosity. In general, it can be noted that an
enhancement of the porosity requirement S for components under static stress mainly
leads to increased efforts for production D for components under dynamic stress
and testing, and therefore to increased mainly
costs. F for components with special requirements
on functional surfaces

Page 4, VDG Specification P 201


G for components without further specified The localised porosity diameter is
requirements greater than the maximum permissible
size of single pores.
Porosity: The distance between adjacent pores is
The porosity parameter for the surfaces smaller than the diameter of the
agreed upon states the maximum permissible smallest of these pores.
porosity in percent for the load cases G, S and
D, and the maximum permissible number of C Excess material. This parameter can
defined pores related to a reference surface only be used in connection with the
for the load case F. The reference surface is diameter parameter. Localised porosity
always square, triangular (isosceles) or round, is only permissible in excess material
with its shape depending on the respective and joint areas (heat centres = C).
component geometry (see Figure 2 and
5.1.2). R Component wall centre area. The
parameter R is only permissible for pore
Diameter: classes D10 to D30. (e.g. D10: mainly
The specification of the diameter parameter is dynamically stressed with a maximum
optional. It specifies the maximum permissible permissible porosity of 10 %) The
comparison diameter of single pores. specified porosity class only applies to
Optionally, manufacturer and customer can the centre area (R) of the component
agree on the mean length or on the mean wall (inner third of the relevant wall
pore diameter or on the equivalent diameter. thickness). In the two outer thirds
(The comparison diameter is the smallest porosity class D4 shall be adhered to.
diameter possible including all pores; the
equivalent diameter is the diameter of a circle Pn Pore size. This parameter can only be
of the same area.) used in connection with the diameter
parameter. The maximum permissible
Additional parameters: pore size (defined by the diameter
The specification of the additional parameters parameter) only applies to the
Z1 to Zn (from German "Zusatz") is optional. component wall centre area (inner third
They can be used separately or in multiple of the relevant wall thickness). In the two
combinations and assume the following outer thirds the maximum permissible
values: pore size (P) of single pores is limited to
a diameter of n mm. In pore class F, n
An Distance between adjacent pores. specifies the diameter up to which pores
This parameter specifies the minimum are not considered.
edge distance between two adjacent
pores. The minimum edge distance is Representation:
the diameter of the smaller one of two (load case)(porosity)/
adjacent pores multiplied by the factor n [diameter]/[add. parameter 1]/ [...] /[add.
in mm. (A = distance; from German parameter n]
"Abstand") The value for n shall be e.g. S5/2/C or F4/3/A0.5/P0.8
agreed upon by manufacturer and
customer. In order to describe the permissible pore class
sufficiently, at least the parameters in round
M Centre of the component wall. This brackets are to be specified. The parameters
parameter can only be used in in square brackets are optional.
connection with the diameter parameter.
Localised porosity is only permissible in 5.1.2 Reference surfaces for the pore
the centre (M; from German "Mitte") of classes
the component wall. Localised porosity
is an accumulation of single pores. When the component is cut in view for pore
Necessary prerequisites for the class F the functional surface is considered
presence of localised porosity are: this results in an area which can be divided in
squares, triangles (e.g. isosceles) or circles.
The respective reference surfaces of these

Page 5, VDG SpecificationP 201


sub-areas shall be chosen in such a way that 5.1.3 Porosity class determination
they cover a maximum surface and fit the
The determination of porosity classes
outer contours of the sub-areas (Figure 2)1.
according to this specification entails costs for
Around bores and threads the reference
mandatory testing which have to be assessed.
surface is the largest ring area around the
bore/thread, if the bore/thread is cut at right
angles to the longitudinal axis. In this case, 5.1.3.1 Pore class S (for static stress)
the thickness of the ring is considered as a Specimen preparation as well as the optical
common wall thickness. resolution used for porosity testing of pore
class S shall be agreed upon between caster
In addition, the following is required for pore and customer. Agreements should preferably
classes D1 to D4: be documented in the corresponding
component drawings or in a test specification.
In none of the sub-areas of the respective In case of doubt, class S porosity shall be
reference surface (sub-area with optional evaluated on a plane surface with a medium
location within the reference surface, peak-to-valley roughness of at least Rz 25,
dimension of the sub-area = 3 mm x 4 and a resolution corresponding to that of the
mm), the portion of surface porosity may naked human eye.
exceed 4 % (in addition to correspondence
with the class-specific porosity). This is not
required if the reference surface is too 5.1.3.2 Pore class D (for dynamic stress)
small. If not otherwise agreed upon between caster
and customer, for a porosity specification of
Pore classes D1 to D4 should only be used class D, porosity is always evaluated on a
in especially critical component areas and metallographic microsection with a
in exceptional cases (see also 5.2). magnification of 25 : 1 or 20 : 1 under a
microscope.
For all other areas pore classes D5 and
higher are recommended. Porosity classes D1 to D4 are exclusively
evaluated on a metallographic microsection
with a magnification of 25 : 1 or 20 : 1.
Reference surfaces If no special testing cross section is specified
Sub-area of in the component drawing, the specification
reference applies to all cross sections of the respective
surface component.

5.1.3.3 Pore class F (special requirements


on functional surfaces)
Sub-area of the component section

If not otherwise agreed upon between


manufacturer and customer, the porosity of
Figure 2 Section of a component with this pore class is evaluated with the naked
pores and respective reference eye on the finished functional surfaces.
surfaces for porosity
determination (see also 5.1.3.4 Pore class G (components without
examples in Annex 3) further specified requirements)
If not otherwise agreed upon between
manufacturer and customer, the porosity of
this pore class is evaluated with X-rays on a
system with a focal spot 1 mm. The
1 generated X-ray image is evaluated as a two-
Rectangular reference surfaces are permissible if
agreed upon by manufacturer and customer.

Page 6, VDG Specification P 201


dimensional cut surface of a component and For a casting the general porosity
divided into reference surfaces acc. to 5.1.2. specification S5/2/C is noted in the drawing.
Furthermore, the additional parameters
If not otherwise agreed upon between F4/3/A0.5/P0.8 acc. to the drawing apply to
manufacturer and customer, the reference one of the three functional surfaces of this
surfaces selected this way shall not exceed 5 casting. This specification means:
cm2, with observance of the ratio X-
ray : casting = 1 : 1. In the case of deviating A maximum permissible porosity of 5 %
ratios the maximum size of the reference applies to the whole statically stressed
surface shall be adapted accordingly. component. In the component, single
pores up to a maximum diameter of 2 mm
5.1.4 Examples for pore class are permissible. Localised porosity is only
designations permissible in excess material and joint
areas (heat centres) (example 2).
Example 1: General designation
In the specific functional surface a
maximum of 4 defined pores per
reference surface are permissible. The
add. parameter n maximum permissible single pore
add. parameter 2
diameter is 3 mm, the minimum edge
distance of the pores to each other is 0.5
add. parameter 1
x diameter of the smallest of two adjacent
pore diameter
pores. Single pores up to a diameter of
porosity 0.8 mm are not considered (example 3).
load case

5.2 Test options


For evaluating the porosity of castings,
Example 2: Designation S5/2/C various test methods can be used. The test
method should be specified between
manufacturer and customer in connection
with the specification of evaluation criteria
Localised porosity in joint area and while taking into consideration the
access material permissible
component requirements. [1]
max. permissible pore diameter: 2 mm
max. permissible porosity: 5 % 5.2.1 Radiographic test with image
mainly static ally stressed intensifier (RT)The radiography test (X-
ray test) [2, 3, 4, 5] is a nondestructive test.
The resolution of this test method depends on
Example 3: Component with special requirements the wall thicknesses to be tested, the distance
F4/3/a 0.5/P 0.8 and angle of radiography and the casting
geometry. In the X-ray test a two-dimensional
projection of the casting is created. This
causes problems in pore localisation and
Pores up to a diameter of 0.8 mm identification. The maximum resolution of
not considered standard X-ray systems used in foundries is
Minimum distance betw een tw o approx. 0.5 mm.
pores: 0.5 x of the smaller pore
Per missible single pore diameter:
3 mm 5.2.2 Ultrasonic test (UT)
Max. four defined pores per The ultrasonic test is a nondestructive test [6].
reference surface
The resolution depends on the casting contour
Component w ith special functional
surface requir ements
of the wall thicknesses to be tested as well as
on the ultrasonic distance and angle. In the
ultrasonic test a one-dimensional projection of
the casting is created. A total overview of a

Page 7, VDG SpecificationP 201


component can only be generated by ground surface, on a milled or turned surface
scanning the entire component. During or on a polished microsection. The resolution
ultrasonic testing, complications can occur of this method depends on the appearance of
when the transducer is coupled and when the the considered surface and on the auxiliary
reflected signals (determination of size, means used for evaluation. The
number and position of pores) are evaluated. metallographic test and section test only allow
Therefore, this porosity specification method an evaluation of porosity in the considered
is only applicable in special cases. section plane. Therefore, this test is only
suitable for increased requirements in critical
5.2.3 Leak tightness test (LT) component areas.

The leak tightness test is a nondestructive test The metallographic test is the method
[7, 8]. It is applied when leak tightness under providing the highest level of information
pressure is required for a casting . The leak concerning critical component areas, as it
tightness test only makes sense if special gives the most detailed information on the
requirements for the leak tightness of a causes and origins of porosity and further
component are evident. influences on microstructure.

5.2.4 Visual test (VT) This test method is very complex and
therefore cost-intensive; it requires
The visual test is a nondestructive test. Its especially careful execution [20, 21].
resolution depends on the test equipment
used (e.g. magnifying glass) [10]. The visual The fact that pores might be filled by excess
test is performed on the rough contour of the material due to grinding, cutting or polishing
casting or on machined surfaces. A has to be observed. This can lead to
quantification of general porosity is not misinterpretation.
possible using this test method.

Specialised staff is required for the following 6. Drawing notes


nondestructive test methods:
RT (Radiographic Testing) In drawings, pore classes are to be specified
UT (Ultrasonic Testing) according to 5.1 for the entire component or
LT (Leak Tightness Testing) for special areas.
VT (Visual Testing)

6.1 Collective notes


5.2.5 Density test
According to this specification, collective notes
The density test is a nondestructive test. This
of the maximum permissible porosity in % are
method only allows the identification of the
possible for the load cases S, D and G
portion of volume porosity in the entire
defined in 5.1.1. For pore classes D1 to D4,
component. Pore size and location can only
collective notes are not permissible. A
be determined for single segments by cutting
collective drawing note shall be situated near
(destroying) the castings. As in general the
the title block, with the specifications of load
density test is performed with water according
case and maximum permissible porosity being
to Archimedes' Principle, this method does not
mandatory. Porosity acc. to VDG specification
allow a quantification of open pores. The
P201 (see 5.1.4):
density test in general is suitable as an
auxiliary means for production optimisation. A / B [ / D / Z1 / ... / Zn]
Example (see 5.1.4, example 2):
5.2.6 Metallographic test and section test
Porosity: VDG-P201 S/5/2/C.
The metallographic test and the section test
are destructive tests. They can only be A collective note shall only be used for the
performed on random samples. Evaluation is mainly occuring porosity in the
performed on a saw section, on a coarsely casting.

Page 8, VDG Specification P 201


6.2 Notes for defined areas 7. References, standards,
Notes for defined areas can be required by guidelines
the load case or by a functional surface. For
pore classes D1 to D4 and load case F notes [1] DIN EN 1559-1
for defined areas are necessary (see 5.1.1 Founding Technical Conditions of
and 5.1.2). Delivery Part 1: General.
[1a] DIN EN 1559-4
According to this specification the note shall Founding Technical Conditions of
have a local reference: Delivery Part 4: Additional
Requirements on Aluminium Alloy
Castings.
Graphical sy mbol for porosity
[1b] DIN EN 1559-5
Founding Technical Conditions of
stress type
max. permissi ble porosi t y
Delivery Part 5: Additional
max. pore diameter Requirements on Magnesium Alloy
addi tional parameters
Castings.
[1c] DIN EN 1559-6
Founding Technical Conditions of
Delivery Part 6: Additional
Requirements on Zinc Alloy Castings.
Example (see also examp le 3 in 5.1.4)

[2] DIN EN 444


Non-destructive Testing, General
Principles for the Radiographic
Examination of Metallic Materials Using
X-rays and Gamma-rays

[3] DIN EN 12681


Founding Radiographic Inspection
Near the title block of the drawing a reference
to VDG specification P201 shall be given as [4] ASTM E 155-95
necessary, using a collective note according Standard Reference Radiographs for In-
to 6.1. spection of Aluminium and Magnesium
castings.

[5] ASTM E 505


Standard Reference Radiographs for
Inspection of Aluminium and
Magnesium Die Casting.

[6] DIN EN 583-1


Non-Destructive Tests Ultrasonic
Examination Part 1: General Principles

[7] DIN EN 1593


Non-Destructive Tests - Leak Tightness
Test Bubble Emission Technique.

[8] DIN EN 1779


Non-Destructive Tests Leak Testing
Criteria for Method and Technique
Selection.

[9] ISO 10049

Page 9, VDG SpecificationP 201


Aluminium Alloy Castings; Visual Werkstofftagung 91, Mnchen, 4./5.
Method for Assessing the Porosity. Mrz 1991.

[10] ISO 3058 [18] Ostermann, H.: Schwingfestigkeit ge-


Non-Destructive Testing Aids to Visual kerbter Flachstbe aus der Alumi-
Inspection Selection of Low-Power niumlegierung. AICuMg 2 (3.1354.5) im
Magnifiers Bereich zwischen 106 und 107
Lastspielen Fraunhofer-Institut fr
[11] ISO 10135 Betriebsfestigkeit (LBF), Darmstadt
Technical Drawings Simplified Technische Mitteilungen TM-Nr. 38/68
Representation of Moulded, Cast and (1968)
Forged Parts.
[19] Dieterich, K.: Schwingfestigkeit von
[12] Sonsino, C. M.; Dietrich, K.: Einflu der hchstfestem Aluminiumgu. Fraun-
Porositt auf das Schwingfestigkeitsver- hofer-Institut fr Betriebsfestigkeit (LBF)
halten von Aluminium-Guwerkstoffen. Darmstadt, LBF-Bericht Nr. 7543, AiF-
Fraunhofer-Institut fr Betriebsfestigkeit Forschungsvorhaben-Nr.10449N (Mai
(LBF) Darmstadt, AiF-Forschungsvor- 1999).
haben Nr. 5899 (1990).
[13] Ermittlung der Rizhigkeit von Alumi- [20] Pries, H.: Einsatz der quantitativen Bild-
nium-Guwerkstoffen an Kleinproben analyse zur Bestimmung der Porenge-
unter besonderer Bercksichtigung halte in Aluminium-Druckguteilen. Vor-
einer vergleichenden Auswertung unter- trag auf dem 1. Internationalen Deut-
schiedlicher fliebruchmechanischen schen Druckgutag in Neuss am 13.
Konzepte. Abschlubericht zum AiF- April 2001.
Forschungsvorhaben Nr. 6048, Institut
fr Werkstofftechnik, Gieereikunde der [21] Pries, H.; Helmke, E: Einsatz der
TU Berlin, Berlin 1987. quantitativen Bildanalyse zur
Bestimmung der Porengehalte in
[14] Einflu der Porositt bei Aluminiumgu- Aluminiumdruckguteilen. Giesserei 88
legierungen auf die Schwingfestigkeit (2001) Nr. 12, p. 49 55.
unter Biegebelastung auf die Rientste-
hung und den Rifortschritt. Abschlu- [22] Mertz, Klein, Badwidamann: Druckgu-
bericht des AiF-Vorhabens Nr. 8977, fehler-Katalog Aluminium.
Darmstadt 1997.
[23] Schumacher, F.; Widmaier, T.: Druck-
[15] Hck, M.; Naundorf, H.; Schtz, W.: gufehler-Katalog Zink.
Bruchmechanische Untersuchungen
und Rifortschrittsmessungen an [24] Rudat, M.: Druckgu Fehlerkatalog
lunkerbehafteten, bauteilhnlichen Magnesium.
Proben aus GK-AlSi12. Z. Werkstoff-
technik 14 (1983) p. 325-329.
AiF-Forschungsvorhaben (research projects
[16] Schindelbacher, G.: Einflu unterschied- of the German Federation of Industrial
licher Porositt auf die mechanischen Cooperative Research Associations) can be
Eigenschaften der Legierung GD- obtained from the VDG information centre.
AlSi9Cu3. Giesserei Praxis (1993) Nr. Druckgu-Fehlerkataloge (casting defect
19, p. 381-392. catalogues) can be obtained from the
Steinbeis Transferzentrum,
[17] Sonsino, C. M.; Ziese, J.: Schwingfestig- Arbeitsgemeinschaft Metallguss at
keit von Aluminiumlegierungen in ver- Fachhochschule Aalen (Prof. Dr. F. Klein),
schiedenen Porosittszustnden und Gartenstr. 131, 73430 Aalen, Germany.
Aussagen zum Bauteilverhalten. VDI-

Page 10, VDG Specification P 201


Annex 1 punching, milling, drilling etc. Casting burrs
are thin-walled material accumulations and
Definition of further flaws metal residues adhering to the casting which
result from penetration of the melt in the
A 1.1 Cold flow marks mould parting line or in fitting gaps of mould
inserts or cores during casting.
Cold flow marks are patterns representing the
borders of different feeding flows on the
casting surface. A 1.5 Hot cracks
Hot cracks have a cobweb-like, raised
A 1.2 Stick marks structure on the casting surface. They result
from permanent damage of the die in the form
These are depressions on the casting surface of cracks. These cracks mainly occur in areas
created when one or several thin layers fused of high temperature cycle stress during
with the mould surface are torn out. They casting.
often occur in areas which are extremely
heated during the mould filling process.
A 1.6 Further characteristics of cast
components
A 1.3 Draw marks
Dimensional deviation, incomplete mould
Draw marks result from local material removal filling, volume variation, distortion, inclusions,
and look like score marks and scratches on ejection marks, flow lines, sink marks, lakes,
the casting surface parallel to the direction of forced cracks and spotted surface are further
mould separation. They are caused by friction characteristics of castings.
between the materials when the casting is
removed from the mould and when the core is In this context reference is made to the
drawn. corresponding literature [22 to 24].

A 1.4 Burrs
Burrs include casting burrs and burrs resulting
from the deformation of material during

Page 11, VDG SpecificationP 201


Annex 2 Microstructure examples of pore classes 0, 4 and 8

Pore surface area

8%

4%

0%
Pore class
Density

Figures taken
fromBilder
[12]
Bilder ausaus
[12][6]

Figure A.2.1 Microstructures and fracture structures in the starter crack area of casting alloy G-
AlSi7Mg0.6 wa [12]

Page 12, VDG Specification P 201


Annex 3
For Figures A.3.1 to A.3.4 porosity is
Examples of different porosity in specified for the entire area.
general and in dependence on the
reference surfaces (informative) Figures A.3.5 and A.3.6 contain reference
surfaces with porosity specifications
analogous to Figure 2. In some figures
The microsections are taken from possible reference surfaces are indicated.
components with different requirements
These components have met the
requirements set for them.

Figure A.3.2 Aluminium die casting, round gas


pores, porosity 1 %

Figure A.3.1 Aluminium die casting,


porosity 3 %

Page 13, VDG Specification P 201 revised and updated 2002-10-16


Figure A.3.3 Aluminium die casting, milled Porosity in small square: 9 %
specimen, shrinkage cavities, Porosity in large square: 4 %
porosity 2 % (cavities in joint
area) Figure A.3.5 Reference surfaces for porosity
specification (see 5.1.2), joint
area

Figure A.3.4 Zinc die casting, Porosity in small square: 1 %


porosity 7 % Porosity in large square: 12 %
Porosity in dashed square: approx. 30 %

Figure A.3.63 Reference surfaces for porosity


3
Note on Figure A.3.6 specification (see 5.1.2)
The dashed square makes clear the necessity of (cf. Figure A.3.4)
choosing an area for measurements which is small
enough to cover the relevant area. At the same time,
it has to be large enough to properly represent the
pore distribution.

Page 14, VDG Specification P 201


It is planned to include all types of porosity
occurring in non-ferrous metal castings in a VDG-Fachgruppe 2 NE-Metallgu,
catalogue of examples. This catalogue will Sohnstrae 70, 40237 Dsseldorf,
contain figures which can be assigned to the Germany.
different porosity classes according to this E-Mail: Lothar.Wenk@vdg.de
specification. The users of this specification
are requested to provide such examples with
specification of scale, porosity designation
and requirements for the component to:

Page 15, VDG Specification P 201 revised and updated 2002-10-16

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