There are several problems that arise throughout the process of casting that can lead to failed castings.  While there are some errors that are typically no one’s fault including shrinkage and porosity issues. These problems occur as a result of the defects found within the metal itself like gasses that are trapped within it. However, there are errors caused by the operator that happen during the process of casting that can be prevented:

One of the most common operator errors is mold shift, which is kind of exactly what it sounds like. If there is a misalignment in the cope and drag of a pattern, it will lead to a defective casting.

It then becomes the responsibility of the operator to make sure that the cope and drag is perfectly aligned; however, there are also ways by which this error can be prevented. The most common method to prevent a mould shift is making use of some type of alignment to ensure the cope and drag is aligned perfectly.

Alignment pins are used on all our mold patterns to save time and money. The operators who are making the castings cannot take the time to ensure every mold is perfectly aligned because of lack of time to carry out similar job orders. Therefore, alignment pins are included on their patterns and also the alignment pins can differ foundry-wise.

But it should be noted that ensuring the cope and drag is aligned can be, at times, tricky and needs a lot of trial and error. Once you’re able to make an accurate casting, the cope and drag should be marked so that you can align it conveniently to make the next casting. But above all, the operator should take his time and check twice so as to pour once.