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How to Eliminate Carbon Black Formation in Casting

2026-02-03

Causes of Carbon Black Formation

1.Incomplete combustion of the foam pattern
Localized poor vaporization of the EPS pattern during pouring.

2.Poor foam pattern quality
Inadequate density or inconsistent material properties of the foam.

3.Low pouring temperature
The metal temperature is insufficient to match the foam vaporization rate.

Solutions

1.Optimize the gating and riser system design
During pouring, an improperly designed gating and riser system may cause uneven molten metal flow, with excessive metal entering certain areas of the mold while other areas receive insufficient flow. This leads to localized poor foam vaporization and results in carbon black adhering to the casting surface.
The gating and riser system should be designed according to the casting’s section sequence so that the foam pattern can vaporize effectively under the radiant heat of the high-temperature molten metal, thereby preventing carbon black formation.

2.Control foam pattern density
The foam density should be maintained at 14–16 kg/m³ to ensure good vaporization performance.

3.Use appropriate pouring temperature and speed
Pouring temperature and rate should be properly matched so that the foam vaporization rate is balanced with the vacuum extraction capacity. This ensures that combustion gases are discharged promptly, preventing carbon black accumulation.

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