The die casting industry manufactures more than a third of all metal castings. As an essential part of the much larger metal casting industry, die casters provide more than 50,000 jobs.
A high level of technical expertise and accuracy is essential to be part of the fast-growing die casting industry. These competencies help in preventing die-casting mistakes. Errors in the die-casting process can result in huge losses for the company.
Identifying errors and knowing how to prevent them is key if you wish to participate in the $57.12 billion die-casting industry. Keep reading to discover seven of the most frequent die-casting errors and ways to prevent them.
Blisters appear like small protrusions on the surface of the material. The size of blisters may vary based on the cause of the problem. Mistakes in casting, pre-finishing, or electrodeposition cause this die casting error.
Casting blisters are brought about by impurities in the alloy, intergranular corrosion, surface porosity, or cold laps. To solve the issue of casting blisters, you need to lower the surface porosity.
Pre-finishing blisters in die-casting parts can be caused by surfaces that are not perfectly clean. In this case, blisters develop after electrodeposition. Avoiding delays between the processes of casting, cleaning, and electrodeposition will reduce the likelihood of surface oxidation.
Traces of oxidation can still be present on the surface after taking the necessary precautions. If this occurs, you can clean it with acids or eliminate it through mechanical vibrating.
2. Using Low-Quality Pressure Sensitive Adhesives (PSAs)
PSAs for die-casting are different and have a difference in their performance. Using the wrong adhesive negatively impacts the end-product. Being specific about the PSA that your gasket converter requires for application is a great way to avoid end-product mistakes.
There are some specifications that an expert in the die-casting process should consider when choosing an adhesive. They include temperature, product longevity, and strength of adhesion. Sometimes, a private label PSA might be recommended for use.
Before you commit to the purchase, make sure that the PSA will work for your project. Always choose the adhesive option that is of high quality and caters to your application needs. Many PSAs are of good quality but have a low cost.
Some hot stamping dies also share the same trait as good PSAs; low cost and high quality. Click here to take a look.
3. Over-Reliance on Die Cut Gaskets
Die-cut gaskets might not always be the best solution for your project. In some instances, up to 75% of materials used in gasket manufacturing go to waste. A custom molded rubber gasket could be a good replacement for wasteful die-cut gaskets.
A gasket that is extruded and spliced can work well for huge applications that are shaped irregularly. Other gaskets are form-in-place and result in fewer problems when working with narrower gasket walls. These gaskets help save money while leading to fewer issues.
Professionals must be knowledgeable about different manufacturing alternatives. This is especially important when working with highly-priced materials. Form-in-place gaskets are an amazing and economical gasket production method.
4. Using the Wrong Drafts for Die-Casting Parts
Draft refers to the amount of taper provided in cores or other sections of the die cavity. Drafts are important in ensuring ease of removal of the casting from the tool. Draft requirements vary with the type of surface, its depth, and the alloy in use.
The draft used also varies for holes, out walls, and inside walls. Untapped holes need the most drafts. Inside walls require an intermediate draft amount, while outside walls need the least draft amount.
Applying the correct amount of die-casting drafts makes it easier to open the die and smoothly eject the casting from the mold. When a die is easy to open and eject from surfaces, it results in more accurate die casting with greater surface quality.
The draft you use should begin at the parting line. You must also know how to use the draft before starting the procedure.
5. Applying Insufficient Clamping Force
The clamping force is an important aspect in selecting an appropriate die casting machine. This force is essential in keeping the mold in place and avoiding splashing by the molten metal. It’s also vital in controlling the bulging force in the cavity and ensuring measurement precision in the casting.
In some cases, producers pay little to no attention to the clamping force of their casting machines. Such negligence leads to metal splatter and a mess in the die-casting process. Metal splatter leads to scruffy-looking edges.
Additionally, you will spend so much time leveling the shabby parts. Selecting the correct clamping force is essential in avoiding these die-casting mistakes.
Some principles can be followed to make sure you choose a die casting machine with the appropriate clamping force. Make sure the two die halves are properly fastened. This ensures that the applied molten stays within the two dies.
6. Incorrect Design
The die-casting process ends when the correct finishing is applied. Finishes are used on die-cast parts to enhance their appearance or the functionality of the component. The die-casting industry is filled with numerous die-casting finishes that you can choose from.
Post-cast processes help in removing round protruding edges and making surfaces brighter. Automated and mechanical deburring procedures can be used to attain this kind of finish.
A different kind of finish involves coating. It involves sealing, protection from corrosion, and insulation. A lot of the coatings used in this process are paint and plating-based. The quality of the finishing design is directly related to the quality of the surface found underneath.
You need to compare a variety of finishing designs to choose the correct one for your product.
The product of your die-casting process should be uniform. Selecting the correct design contributes to the uniformity of your final product. Designing parts that have varying degrees of thickness is a mistake that leads to end-products that are not uniform.
The best way to avoid the non-uniformity of die-casting parts is to ensure all your designs are consistent. However, you may need to create products with variations based on their functionality. This will require you to make continuous changes in your design to achieve the required thickness.
Avoid Die-Casting Mistakes
For professionals who have had years in the industry, die-casting is an easy process. However, for some, the process might seem challenging. They might also make mistakes in the process which impact the end-product.
It’s therefore important to understand the different die-casting mistakes that can occur. Knowing how to avoid these mistakes can help you get better at your craft. Knowledge of die-casting errors and their fixes can help you design appropriate quality control measures.
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