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Like hot tears, internal cracks are produced when the metal is reheated. This is due to the formation of a solidifying skin on the surface of the metal, so that it becomes distorted as it solidifies. If the distortion is large enough, the metal is able to crack. This is not a normal type of crack and does not occur in solidification.

A pinhole creep fracture is a hole in the cast, like a soup can cheat, caused by inhomogeneity in the solidifying metal. When the metal was poured into the mould cavity, it was under higher pressure than the surrounding material, and, thus, remained tight. However, as the metal solidified, it shrank more than the surrounding material, causing the material to be pushed out of the mould and cause the defect. This type of defect is common in permanent moulds.

A web defect is caused by unbonded grains or segregated particles within a molten metal stream. Web defects occur at the solidification interface and can be spherical or wedge shaped. These defects are most common in hot or warm pouring, but they are also formed in raw metal pouring. They can be avoided by sufficient necking for the pouring.

A wing defect is a mode of failure of an ingot or casting due to the formation of excessive meniscus in the liquid metal. It can occur due to inadequate necking in the pouring. The meniscus forms around the pouring opening, which partitions the body of metal into two lobes. Usually, the wider the lobe, the greater the meniscus. A meniscus exceeding half of the width of the stream is indicative of a defect. To avoid this defect, small enough moulds are desirable, and necking should be adequate.

A crack in one or more surfaces is the failure of a hole or holes to be sealed. It is due to stress concentrations in the plug and/or the joint attacking the plug. It is due to accumulation of stresses from use or handling. A cracked hole does not necessarily have to heal. The plug surface may become smooth due to pinch-off. If the plug does not heal, the stress build-up may cause failure of the joint in the future. d2c66b5586

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