Knowledge of Die Casting Products Process, Manufacturing and Product Inspection (Updated)

Die casting – WikipediaDie casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process.

Part inspection is crucial before sending out diecast parts to the customers to ensure the finished part’s quality and accuracy. Some of the defects involved in diecast parts include surface defects, inclusion defects, molding, and pouring defects, shrinkage, cavities, tears, cracks, and many more. During the process, quality assurance helps detect any flaws that may have occurred so that corrective measures can be taken to remove the defect in the other units. Finally, finished product inspections are done after the castings have been completed to ensure that the part meets all the customers’ specified requirements.

Die Casting Products Material Range:

  • Aluminum Alloy (Aluminium): A380 / ADC12 / ALSI10MgMn / ALSI9CU3 / ZL104 / ZL102 / A390 / ALSI12FE
  • Zink Alloy: Zmak2, Zmak3, Zmak5, Zmak7 / ZA8, ZA12, ZA27, ZA35 / ZZnAl10-5, 9-1.5, 4-1, 4-0.5, 4 / Z35530, Z33520 / ZCDC1,ZCDC2 / GD-ZnAl4Cu1 GD-ZnAl4 / Z-A4U1G Z-A4G / UAM10-5 UAM9-1.5 UAM4-1 UAM4-0.5 UAM4
  • Copper Alloy: Brass Alloy / Bronze Alloy / Cuprum Alloy

Die Casting Machine Size:

80ton – 1600ton

Die Casting Products Follow-up Process (Optional):

  • CNC Machining:
  • Surface Treatment
  • Porous Sealing
  • Heat Treatment
  • Testing Location
  • Testing Items

Die Casting Products Final Usage of Products

  • Aluminum Die Casting Gearbox Casing Products
  • Aluminum Die Casting Motor Housing Products
  • Aluminum Die Casting Engine Block Products
  • Aluminum Die Casting Pump Housing Products
  • Aluminum Die Casting Bicycle parts Products
  • Aluminum Die Casting Hang Glider Airframes Products
  • Aluminum Die Casting Power Tool Housing Products
  • Aluminum Die CastingAviation Parts
  • Aluminum Die Casting Auto Parts
  • Aluminum Die Casting Radiator Products
  • Aluminum Die Casting Radiation Fin Products
  • Aluminum Die Casting Heat Sink Products
  • Aluminum Die Casting Cooling Fin Products
  • Aluminum Die CastingRadiating Fin Products
  • Aluminum Die Casting Thermal Slug Products
  • Household Parts
  • Cooking Parts
  • Industrial Parts
  • Auto Parts

Other related products: Aluminum Casting Parts, Aluminum Alloy Casting, gravity die Casting, auto parts and components, air compressor, housing for power resistors, handles for switching power supplies, clips, Aluminum front panels, terminals, turning parts, fuse holders, etc.

Die Casting Products Manufacturing Process:

  • 1. Mould /Tooling analysis, design & manufacturing
  • 2. Mould /Tooling testing & confirm the sample
  • 3. Die-casting rough parts
  • 4. Precision machining: CNC lathes, milling, drilling, grinding, etc
  • 5. Surface treatment: Trimming, polishing, cleaning, passivation & power coating and other requirements from Customer
  • 6. Full Inspection
  • 7. Packing

Knowledge of Die casting products manufacturing and quality inspection

Die Casting Products Packing & Shipping

  • 1.Bubble bag packaging
  • 2.The second floor is packed with cartons
  • 3.Wooden package, plastic package, carton package, vacuum package, or as client required.

All packaging is to ensure that the transport process, the product was not worn or deformation

General Inspection Checklist for Die Casting Products Pre-shipment Inspection:

  • 1. Appearance quality: the surface of the product shouldn’t have visible defects(scratches, burrs on edge, holes, etc)
  • 2. Quantity check
  • 3. Workmanship check: defective list
  • 4. On-site tests(Barcode scan test, plating or coating thickness check, drop test)
  • 5. Material check
  • 6. Measurement check: size & weight
  • 7. Shipping mark & Packing check
  • 8. Assembling check
  • 9. Basic function test

Product Testing For Die Casting Quality Assurance

Defective die cast parts may be either reworked or completely scrapped and remelted into their original material, depending on the nature and extent of the defect. The inspection methods may be classified into destructive and non-destructive.

A. Destructive testing.

Destructive methods generally involve destroying, sawing, or breaking the castings. These are broken within the areas where voids or defects are suspected. In addition to finding voids, diecast parts may also be subjected to destructive testing when inspecting for the material strength. The main disadvantage of destructive tests is that a sample from a selected area/ piece may not represent the entire lot’s behavior.

B. Non-destructive testing.

This inspection method does not involve cutting or destroying a work part. Non-destructive testing allows testing all the casted parts. Because of this reason, NDT is generally favored by many. Below are the common non-destructive testing methods:

a. Visual Inspection:

This involves inspecting the surface of the casting without using advanced inspecting equipment. This procedure relies on examining with the naked eye or sometimes with a magnifying glass or microscope. The surface defect this can indicate are the obvious ones like blow holes, fusion, swells, external cracks, and mismatch.

b. Dimensional Inspection:

Dimensional accuracy should always be inspected, especially for metal parts with critical applications in the industry. This is done to ensure that the castings produced have conformed to all the overall dimensions, including machining allowances. Dimensional inspections may be inspected using calipers, micrometers, comparators, height gauges, and even a CMM (Coordinate Measuring Machine).

c. Magnetic Particle Testing:

This testing method is used to detect cracks in diecast parts like iron and steel, which can be magnetized. During the test, the casting is magnetized, and then fine particles of iron and steel will be spread on its surface. An interruption of the magnetic field and leakage of magnetic flux is an indication that there is a crack or void in the casted part. Small cracks not detected by radiography can be quickly revealed by magnetic particle testing.

d. Penetrant Testing:

Unlike magnetic particle inspection methods where the inspected materials are only limited to magnetic materials, penetrant testing methods can detect small cracks and voids on any material. The cast parts to be tested are covered with a penetrant testing liquid. This liquid has an outstanding penetrating ability to seep through the finest cracks and voids called capillary action.

e. Ultrasonic Testing

This inspection method finds the defects by utilizing high-frequency acoustic energy transmitted into the diecast part. The sound waves travel through the metal until it hits another surface (it may be the opposite side, or it might be a defect or void). Any barrier will reflect the soundwaves and will be recorded for a technician to analyze. The wave deflection pattern indicates any noncontinuity on the material, therefore making it possible to trace the exact location and size of the internal defect.

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