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Casting information--flange

September 25, 2024
1. Casting information:
casting name:flange
casting requirements: surface requirement
casting process:
Die Casting machine tonnage:300
punch diameter mm:50
alloy material:ADC12
casting size mm: 160*30 mm
average wall thickness mm:4
2.Casting problem
air tightness,big difficulty to adjust machine. the area around gate was teared when no porosity. See the defect position picture.
3. Casting pictures
pic 1 front top viewCasting pictures
4.Casting analysis
This case is a casting with air tightness requirements. Due to the design of the pouring system, large pre-filling and large process production are required in die casting production, otherwise the porosity ratio is very high. In the process of pre-filling, the dense layer on the surface of the product is not high or there is no dense layer , and the surface of the product has a pattern similar to orange peel. Due to the process is similar with low pressure die casting , the internal density is good and the porosity ratio is low. The reason for the sticking mold is that the surface strength of the product is not big, which is less than the friction force of core.
5. Improving measures
Due to the limited layout of the mold, the room for improvement of the mold pouring system is limited. It is suggested to improve the process. Or re-open the mold.
1, control mold temperature, reduce mold temperature near the gate.
2. Appropriately increase the draft, and do nano coating treatment after polishing the die, in order to reduce the holding force.
3. If re-open mould, it is recommended to use the middle pouring scheme of the three-plate mold.
6. Tips
For porosity
When other conditions are fixed, the greater the gate speed, the greater the degree of atomization, the more dispersed the porosity inside the casting (although the overall gas content is rising), which is also the reason why some die casting masters use a larger speed pressure to hit the product. This  method can let casting be qualified , but at the same time, the life of the equipment and mold will be greatly affected.
 
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