Die-castings production includes various steps of processing. If any step is not properly executed, it can result in a defective casting. The process of die casting and repairing bad casting process, both are expensive. So, while manufacturing, you need to be very careful to avoid die casting manufacturing problems. It is a precision casting method. The production of parts by die-casting has low dimensional tolerance and high surface precision. Small arts like typewriter parts, general camera parts, and complex vehicle parts like locomotive, automobiles, and airplanes are mostly manufactured by the precision die casting manufacturer. The quality of casting in manufacturing different parts affect the skills of the operator and quality management and equipment.
Some common defects occur during the die casting manufacturing process and their solution.
The process of die casting production, the mold is targeted by heat repeatedly. So, the molding surface of the product and its internal deformation cause micro-cracks occurred. Therefore, the die casting mold must be sufficiently preheating die casting at the die casting. Moreover, the mold should maintain within a certain range of operating temperatures during the process of die casting to avoid the problem of early crack failure.
The die-cast process goes through the action of the injection force, the mold of the casting crack at the weakest point. It occurs especially at the scribing marks or electro machining marks on the surface of the molding. The mold is not polished or the fine cracks appear at clear corners first of the molding.
When the grain boundary has coarse grain or a brittle phrase, easily it can break. The cracks propagate during brittle fracture rapidly, which is a very dangerous factor for mold failure. Therefore, for this reason, electric machining marks, and scratches, etc. on the surface of the mold must be polished. The surface should be polished evenly even if it is in the system of pouring. The molding materials used in die casting required to have good plasticity, high strength, fracture toughness, and impact toughness.
Flash, fin, and husks:
One of the most frequently occurring defects of casting is flash and injection molding defects. It is casting fin or burrs that occur when any unwanted and excess materials attached to the cast. Typically, it’s a thin sheet of metal that practices at the parting faces. Flash is the waste material after being re-melted that turns into dross.
It is due to crack or gap on the core surface of the casting. Improper clamping of the flask or insufficient weight on the mod can lead to a gap. To prevent this issue, reassemble the mold and cores. There should be enough weight on the top of the mold so the two parts fit tightly together. It can be minor to a very serious issue while manufacturing. Manufacturers can remove flash by hammering and breaking it off and filling it down to the parting line if the flash is minor.