One of the most widely used methods for forming intricate technical parts in heavy machine building, railways, automobile industry, and aviation is casting of metals. But defects, such as blowholes, inclusions, shrinkage porosity, cold shuts, porosity, and misruns, affect the mechanical properties, geometrical accuracy, quality of products, and cost of manufacturing significantly. In order to minimize the formation of defects, this paper attempts to identify common defects that occur in the process of metal casting and proposes ways to improve the process. The experiments involved sand casting procedures and varied pouring temperature, moisture content of the mold, and gating systems. Results indicate that there is an enhancement in the quality of casting due to changes made in the process parameters. The study contributes significantly towards improving the output capacity of industries, reducing waste, and increasing efficiency.

Keywords: Metal casting, casting defects, process optimization, porosity, shrinkage, sand casting, quality control, foundry engineering.