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13 Common Defects in Die-Casting Products And Their Solutions

Views: 50     Author: Site Editor     Publish Time: 2023-01-15      Origin: Site


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1、Surface of the casting has patterns and visible traces of metal flow.



The runner directing towards the casting inlet exhibits inadequate depth. There's an overbearing shot-to-shot pressure ratio, inducing an excessively swift metal flow rate, culminating in metal splatter.

Adjustment Methods:

Increase the depth of the gate runner. 

Lower the shot-to-shot pressure ratio.

2、There are small protrusions on the surface of the casting.



Irregular surface texture. 

Presence of scratches, pits, or cracks within the mold cavity.

Adjustment Methods:

Perform polishing on the mold cavity.

Alternatively, replace the mold cavity or conduct necessary repairs.

3、The casting surface has ejector pin marks, and the surface is not smooth and rough.



Shorten the ejector pin (or core pin) to the appropriate length.

Clean and smooth the mold cavity surface, removing any roughness or foreign objects.

Adjustment Methods:

Modify the length of the ejector pin as needed.

Thoroughly polish the mold cavity to eliminate any foreign objects and remove oil contamination.

4、The casting surface has cracks or localized deformations.



Uneven or insufficient distribution of top pins results in uneven stress.

Uneven stress occurs when the ejector pin fixed plate tilts during operation, particularly on one side.

Deformation arises from excessively thin casting walls, particularly post-shrinkage.

Adjustment Methods:

Enhance the number and distribution of top pins to ensure uniform stress distribution during casting.

Realign and reinstall the ejector pin fixed plate for improved operation.

5、There are air pores on the surface of the die-cast part.



Reduce the amount of lubricant applied.

Clear any obstructions from vent holes to allow trapped air to escape freely.

Adjustment Methods:

Apply lubricants sparingly.

Consider adding extra vents or repairing existing ones to facilitate adequate air venting.

6、There are shrinkage cavities on the surface of the casting.



Review the die-casting process for effectiveness to address excessive variations in wall thickness.

Check and regulate the metal liquid temperature to prevent issues.

Adjustment Methods:

Incorporate process holes strategically in regions with differing wall thicknesses to achieve uniformity.

Decrease the temperature of the molten metal for improved casting results.

7、The casting has an unclear external contour, fails to take shape properly, and experiences partial underfilling.



Inadequate pressure from the die-casting machine, resulting in a low shot-to-shot pressure ratio.

Excessive thickness observed at the gate.

Incorrect gate positioning causing frontal metal impact during the casting process.

Adjustment Methods:

Upgrade the die-casting machine to one with a higher shot-to-shot pressure ratio.

Trim down the thickness of the gate runner.

Adjust the gate placement to mitigate frontal impact on the casting.

8、Some portions of the casting are not fully formed, and the mold cavity is not completely filled.



Increase the die-casting mold temperature to optimal levels.

Raise the metal liquid temperature to the required level.

Ensure adequate pressure from the die-casting machine.

Adjust the metal liquid supply to prevent excessive shot speed.

Improve the venting system to facilitate proper air release.

Adjustment Methods:

Optimize the die-casting mold and metal liquid temperatures for improved casting quality.

Upgrade to a die-casting machine with higher pressure capacity to enhance the manufacturing process.

Maintain a sufficient supply of metal liquid, while moderating shot speed, and enhancing the gate runner thickness to optimize production efficiency.

9、Insufficient filling at sharp corners of the die-cast part.



Reduce the size of the inlet for the internal gate to optimize the casting process.

Enhance the pressure output of the die-casting machine to ensure proper material flow and fill.

Improve air venting mechanisms, especially at sharp corners, to prevent air entrapment during the casting process.

Adjustment Methods:

Optimize the internal gate size to facilitate smoother material flow.

Upgrade to a die-casting machine with increased pressure capacity to ensure proper filling.

Enhance the effectiveness of the venting system to prevent air entrapment during casting.

10、The casting has a loose structure and low strength



Increase the pressure output of the die-casting machine to ensure adequate force during casting.

Adjust the size of the inner gating to optimize material flow and prevent restrictions.

Clear any obstructions in the vent holes to facilitate proper air release during the casting process.

Adjustment methods:

Upgrade the die-casting machine to ensure sufficient pressure.

Enlarge the inner gating to optimize material flow.

Inspect and repair any blocked or damaged vent holes to enhance air ventilation.

11、There are air pores or voids inside the casting




Correct the metal flow direction to prevent frontal impacts on the die cavity, minimizing eddies and air entrapment.

Increase the size of the inner gating to regulate metal flow and prevent premature blocking of vent holes.

Adjust the depth of the core cavity to improve ventilation and gas exhaust.

Enhance the exhaust system design to facilitate effective venting during the casting process.

Adjustment methods:

Optimize the size and shape of the diverter cone to avoid frontal impacts with the metal flow entering the cavity.

Expand the inner gating appropriately to regulate metal flow effectively.

Enhance the overall mold design to ensure smoother casting operations.

Rationalize the design of vent holes and increase the number of air vents for improved gas evacuation.

12、Impurities present inside the casting


Impurities present in the metal melt.

Impurities in the alloy composition.

Unclean mold cavity.

Adjustment methods:

Purify the metal melt by removing impurities and slag before pouring.

Consider substituting the current alloy with a higher purity alternative.

Thoroughly clean the mold cavity to eliminate any potential contaminants before casting.

13、During the die-casting process, metal liquid splashes out 


Insufficient tightness between the movable and fixed molds, resulting in a significant gap.

Insufficient clamping force.

Misalignment of the movable and fixed mold plates on the die casting machine.

Adjustment methods:

Reinstall the mold.

Increase the clamping force.

Adjust the die casting machine to ensure that the movable and fixed molds are parallel to each other.


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