I was running a job one day and was surprised to find that one of the three webs was cracked. The center hub is connected to the friction surface by three webs at 120 degrees. I filled out an NCR for it and finished the job. The next time I ran those castings, I again found some cracked castings. It happened again. All the casting were the same date code and so they were all in one batch, from the foundry. I complained to my supervisor that I thought that quality control should be inspecting the casting, so that I do not have to deal with this. They agreed. I asked what is going to happen if I have missed one? Turns out that I did miss one. It made its way to Poland. I have no way of knowing if we have lost a customer due to our poor quality control.
I heard that someone from the foundry, discovered that their technician had been hitting the part with a hammer, to break it away from the sprue/riser and gating. I thought that the problem was solved. Wrong. We received more casting on 2/1 and I found more cracked castings. Six months and the problem is still there. They even changed the radius and they still crack. How can we get these casting for 18 years without this problem and now they crack?
SDE
I heard that someone from the foundry, discovered that their technician had been hitting the part with a hammer, to break it away from the sprue/riser and gating. I thought that the problem was solved. Wrong. We received more casting on 2/1 and I found more cracked castings. Six months and the problem is still there. They even changed the radius and they still crack. How can we get these casting for 18 years without this problem and now they crack?
SDE