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Die Casting News

Video News Update: Advanced Approach to Die Casting Process Control

Posted by Hill and Griffith Company on Oct 23, 2019 7:00:00 AM

NADCA Video News & Information

The material presented in this video are some highlights from NADCA’s online webinar - Advanced Approach to Die Casting Process Control. In this we define what variables we have control of and what impact this has on the many variables that we can’t directly control. This then covers the die casting measurements that should be taken and the great care in choosing the right variables to measure. This data is then used in two ways, 

  • Historical - what was measured in the past and how can the company gain the best information.
  • Planned Trials - what is available to let the company carry out a multi variable experiment and gain the best advantage for future production.

Porosity and X-Ray Score

Transcript excerpt

X-ray score. Not a good idea. This was a classic case where it didn't change by a fall. A company did a large trial and used their X-ray score as the measured output. I advised them not to. They decided that they were going to, because they said, "One is perfect, two is okay, three just failed, four failed a lot." So they did the trial and they sent me the data. After three days of work, 90% of the parts had a rating of two, so there was no variation. What they should have done is say, "In a normal production, what do we get?" Then break those up into a writing scale. Instead, they used their traditional rating scale. So because 90% of the parts had a rating of two, whatever was changed, you've got a: Casting is okay but not perfect. It wasn't helpful.

No matter what we did, we still got twos. So all of the data was a giant load of data at two, and a scattering on either side. You cannot improve things with that. What they should have done is said, within those castings, look at it and say, "What am I really measuring in porosity?" Porosity size is usually a very good thing to measure, or a number of pores within an area. Again, you give it a rating of one, two, three, four for clouds of porosity. You might cut it through and measure pores.

For information on purchasing a downloadable copy of this NADCA webinar in its entirety, please visit: http://www.diecasting.org/store/detail.aspx?id=WEB169

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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight

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