10 Casting Failures Behind Leaks, Porosity & Claims

Leak-tight casting quality control workflow collage showing sand moisture and LOI testing, melt degassing controls, X-ray radiography after rough machining, leak testing, and lot traceability.

Leaks show up after machining, and then warranty costs explode. But most root causes start inside one “bad shift” upstream. Casting leaks and porosity usually come from small process misses, not chemistry alone. Wet cores, unstable reclaimed sand, dirty return scrap, and skipped degassing create hidden pore networks. Buyers cut claims by requiring melt hydrogen/degassing […]

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