Abstract
This paper presents analysis of Micro-Porosity defect in product Crankshaft - Ductile cast iron (FCD 700/2), which has been carried out at one of Automotive Foundry Company in Malaysia. Systematic analyses like cause-effect diagram and defect diagnostic study approach were carried out to understand the root causes of the micro-porosity. From the data analysis there are two significant factors are identified that affect the formation of micro-porosity, they are mold factor and metal factor. Four remedial countermeasures have been proposed to prevent micro-porosity; increase squeezes pressure at molding machine, control sand moisture, increase radius at edge of mold, and reduce Magnesium (Mg) content. Result of the trials showed substantial reduction of micro-porosity defect in crankshaft (casting). The company has accepted the countermeasure and incorporated in the standard operation procedure.
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