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  • Writer's pictureHill and Griffith

Die Casting Defects - Causes and Solutions - NADCA Book

NADCA offers its book outlining the causes of die casting defects and how to prevent them

This is a comprehensive textbook for die casting engineers. This revised version of the defects causes and solutions book has been completely reviewed and revised by world renowned die cast experts William G. Walkington and Dr. Morris Murray. The book includes much more detail on the cures needed to reduce and/or eliminate the defects that plague all die casters. Dr. Murray discusses each defect, in depth, and provides thoughtful solutions to try to help mitigate the problems.

The book has also been updated to include metric units and information on the latest inspection instruments used in the identification and analysis of defects in die castings.

Chapter details are as follows:

  • Review - A review of some of the major operational practices required to reduce or eliminate effects. Just knowing the cause of the defect and asking for a correction won't fix the problem.

  • Surface Defects - Those defects commonly called cold flow or non-fills

  • Laminations - Defects from layers of metal forming during the process

  • Gas Porosity - Internal porosity from trapped gas of various kinds

  • Blisters - Surface manifestation of trapped gas

  • Flow Porosity - Surface or internal porosity from poor pressure conditions

  • Shrink Defects - Porosity from the volume change as the metal changes state

  • Sinks - Surface depressions from shrinkage porosity problems

  • Leakers - Porous sections of the casting

  • Cracks - Visible and not-so-visible cracks in the casting

  • Inclusions - Foreign material that may cause machining problems

  • Solder - Build up of the case material on the die, and damage to the surface condition of the casting

  • Carbon - Deposits other than the cast material on the die causing damage to the surface condition of the casting

  • Erosion or Cavitation - Removal of die steel and subsequent deformation of the casting

  • Outgassing & Edge Porosity - Gas escaping from the casting during a painting or finishing operation that causes defective surface finish

  • Bending, Warping - Deformation of the casting sometime after it is formed in the die cavity

  • Flash - Excessing material extending from a parting line, often accompanied by dimensional deviation

  • Stained Castings - Discolored castings

  • Waves and Lakes - Decorative castings with small imperfections visible only under reflected light

  • Drags - Surface area of the casting is broken by metal stuck to the die

  • Deformations from Ejector Pins - Casting is deformed by ejector pins (pushed pins)

  • Cold Flakes - Leakers and break in at the gate

  • Excessive Flux - Corrosion or porosity from excessive flux

  • Surface Defects - Defects that are caused by surface interaction with the die

To purchase the hard copy or download the e-version of this book, go to the NADCA site.


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