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Die Casting News

Methods and Measures to Reduce the Solder Defect of Die Casting Surfaces

Posted by Hill and Griffith Company on Apr 22, 2020 9:15:15 PM

Excerpt from the January 2020 Issue of Global Casting Magazine

The solder defect in die casting affects surface quality and strength, especially in castings with a high seal requirement. The defect could lead to leakage that would mean more wasted cost (Fig 1.). Four aspects of soldering were analyzed, including:

  • chemical principle
  • mold structure
  • release agent
  • die casting process

For example, JAC die casting company in Suzhou, China, supplies parts to customers that don’t allow solder to be visible to the naked eye. For a German company in Shandong, China, which produces automobile parts, the solder defect area can be no more than 20 x 20 mm. Another company which produces parts with thin walls and high temperature pouring, have found it is at higher risk for solder defects.

What factors cause the solder defect? What’s the physical or chemical change between the liquid aluminum and hot iron mold? This article will share the results of a study on this defect based on the chemical principle, mold structure, release agent and die casting process.

Interfacial reaction is a series of chemical interactions that occur between the interface of two phases, according to chemical type, content, status and properties.

Solder defect is started by the chemical and physic reaction due to the strong affinity in Fe-Al. A new compound is created when the mold and liquid Al connect closely. The higher the temperature, the more intense the thermal vibration of the atoms, causing the solder ratio to rise and the corrosion of the mold to increase, until finally, it causes the solder area. When polished, the surface containing a thin nitride layer will be destroyed, causing worse cycle. Some data in the study showed that the affinity of Fe-Al will become more serious as the Fe element is decreased, creating more solder.

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Tags: Die Casting, Die Casting Release Agents, Die Casting Lubricants, Die Casting Release Agent, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Global Casting Magazine

5 Steps to Identify Casting Defects

Posted by Hill and Griffith Company on Aug 21, 2019 2:38:22 PM

Excerpt from the article in Global Casting magazine's September 2018 issue

The procedure of identifying, diagnosing and minimizing or eliminating crucial casting defects is important for a foundry to run in a low-cost, and high-efficiency mode. It can disprove incorrect conventional wisdom and show that unexpected methods are actually the best way to move forward. To do this, there are three keys to remember:

1. Focus on identifying a casting defect on the basis of its appearance.

2. Be aware of the interactive nature of foundry processes and variables.

3. Use rigorous experimental design methods to study complex causes of defects.

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Tags: Die Casting, Die Casting Plunger Lubricants, Die Casting Lubricants, Die Casting Defects, NADCA, Global Casting Magazine


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