What affects the quality of die castings

[Allen Young]

What affects the quality of die casting parts?

[max green]

1) Design of die castings
The designer should first fully understand the user’s use requirements and working conditions, as well as the stress conditions of the die castings, and then select appropriate materials according to the use requirements and working environment to understand the die casting performance of the materials. During design, special attention shall be paid to making the die casting structure as simple as possible on the premise of meeting the use requirements. The wall thickness shall be appropriate and uniform, and the necessary mold exit slope shall be reserved, otherwise, the defects such as dents, air holes, shrinkage, under-casting stretch marks, cracks, and deformation may be found on the die castings.

The requirements for dimensional accuracy of die castings should be reasonable, otherwise, it will cause unnecessary trouble to mold design, mold processing, the formulation and management of process conditions, and will cause a large number of unqualified products.

2) Mold structure, machining accuracy, and material selection
Die castings are made by molds. There is no doubt that mold design, processing accuracy, mold material selection, etc. are closely related to product quality. The die structure is unreasonable. No matter what measures are taken from the process, it is difficult to make the product qualified. In addition, mold materials, mold processing accuracy, surface roughness, processing traces, micro-cracks in heat treatment, nitriding layer thickness, and improper mold assembly will affect product quality and mold life.

3) Shrinkage of casting material
When the shrinkage of casting materials is generally given in the form of an average percentage or percentage with a certain range of changes, the average shrinkage of materials is usually selected. For high-precision die castings. Special attention shall be paid to the material shrinkage when designing the mold. If necessary, the test mold can be made first. After obtaining the required data on the test mold, we can start to design and manufacture the mold for mass production.

4) Die casting process
The implementation of the die-casting process is related to the quality of the mold and die-casting equipment and the technical level of the operators. Under the condition of existing die casting equipment in China, it is difficult to achieve stable, reliable, and accurate control of die casting process parameters. The basic control of the die casting process is the process of combining and applying die casting equipment, die casting materials, and molds. If the process and main parameters are not strictly implemented, the die castings will suffer from shrinkage porosity, deformation, size disqualification, etc.

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