MAIN CAUSE DEFECT COUNTER MEASURE

PHENOMENON
①Raise the die and metal pouring temperature 。
SHORT FILL Misrun Defect ②reducing parting agent quantity and also do sufficient air blow.
:Metal is frozen before the melted AL solidifies ③increasing the sprue velocity, shortening the filling time.
cavity is filled or by insufficient before filling cavity ④shortening the pressurising time.
metal being ladled. volume. ⑤increasing the final pressurising.
⑥Examining the casting 方案 , change location and size of sprue.
⑦use sufficient gas escaping way ＆ pouring basin.
⑧die surface に shot blast 等かけ , die surface の dissolved metal の flow を
alter 。
COLD SHUT Cold shut ⑨ Get changed product shape, thickness properly from the design deptt.
Metal is frozen when two Melted AL が merging ⑩ Especially, in selective points make sure that thickness is not very thin .
metal fronts join. spot において fully merge ⑪choose alloy of large solidification range.
せず残した境目

湯じわについては above mentioned と similar でよいがよく problem となる

SCALING Scares ので below に mentioned 。
Layers of metal and oxides can If the Molten metal ①Raise die temp 。 For this Die Lubricant 。 Squeeze 内例 .Reduce 外例。
be created by poor shot end divided flow patterns Fasten the cycle time 。 Completely stop water remainants 。
controle and/or bad gate and merging is not proper ②Proper gas escaping during casting must be done 。
runner design. then slight wrinkle occurs. ③Raise the high speed velocity 。
④O/F addition, runner addition

BLISTER (surface or Blister ①Generally if die surface temperature is lowered then the chill time is
subsurface blow hole) Depending on gas increased.
Trapped gases are in the casting entrapped in the casting ②In order to maintain the metal flow (without turbulence) the flow conidtions
when the die is opened when the the swelling occurs on （ speed ＆ high speed stroke) is adjusted 。
castingis still weak. This allows the the cast surface ③The position of spout &O/F is changed so that the metal flow is
conpressed gas to expand and appropriate.Especially gas escape out way should be used.
cause a blister. ④Metal temp,product shape, metal flow velocity, conditions are adjsuted, such
that the some portion of die does not get overheated 。　　　

FLASH Burr ①The casting pressure is lowered.

Metal pressure is too high upon the From casting product a ② Time of increasing pressure is lowered.
projected surfacearea(facing the bit of AL comes out ③ He ﾞ Nt depth of the die is examined and when it is too deep, the height is
plattens)of the casting at the end of which is of no use,this corrected.
cavity fill.This creates a force across occurs because of ④ The injection speed is adjusted (Slow down).
the parting line which is too great for raised core or core ⑤ Whether the metal mold is uniformly heated or not is checked by using UV
the clamping force of the machine. The slide part etc. 。 light sensor.
die is then forced apart which allows
metal to escape.

COLD FLAKES AL solidification ①Burning starts immediatley after pouring the Al in to plunger 。
Metal is allowed to cool too much in process ②The temperature of theMetal is raised (to prevent AL from harden).
the shot sleeve. The solid particles Solidified Al chips inside ③To prevent mixing of chips, the wire net strainer is used in the metal
are then injected into the cavity. These the plunger sleeve get laddle.
flakes are often clearly visible on the mixed in the product
surface of the casting with the naked
eye.

SHOT LUBE STAIN Plunger oil ①use proper quantity of plunger sleeve oil （ reduce ）。
If plunger sleeve is more Proper quantity is mentioned below 。
This defect occurs when too then stain occurs in the 　 350 ～ 800ton M/C 　　 3 ～ 5cc/ ｓｈｏｔ
much shot (tip) lube is used. surface of component 　 1,250ton M/C 　　　　 5 ～ 8 ｃｃ / ｓｈｏｔ

AIR POROSITY Blow hole （ Gas hole ） ①Change spout speed and filling time （ generally pouring fast ）。
This defect is caused by trapped Gas generated from ② Shortening of time of increasing pressure and increase in casting pressure.
air in the casting which can come air,Die lubricant and Al ③Reduce the quantity of die lubricant applied , and the kind of die lubricant is changed.
from several sources. It can be inside the die, get ④Do sufficient air blow 。
caused by poor shot end trapped in the casting ⑤Enlarge spout , pouring basin, gas escape passage as well as change of position ,then change of die partition
controle,poor venting and over and creates big hole. face 。
flow function or bad gating and ⑥Reduce gas and oxide inside melted Al （ melted waste ・ oil are avoided as much as possible ）
runner design.

DRAG MARKS ①while removing Die side wall surface under cut are generated, do sufficient polishing.
Scratch
Insufficient draft or an undercut causing Scratch wound caused ②It is easy to polish in the pull out inclination of the metal mold i.e.,in the component pulling out direction .
a casting to be damaged on the surface on surface of casting ③product part の deep carving こみをなくし ,provide sufficient pull out slope as well as corner part and corner part
when it is ejected.This effect may be when extruded from die roundness.
reduced by changing the temperature at biting metal mold ④Apply sufficient die lubricant. Once again change to the suitable die parting agent （Ｓｉ -wax system is good ） 。
which the casting is ejected.Poor ⑤Heat of die is removed 。 Decrease the die surface temperature 。
⑥ 溶湯の金型溶湯の融着物を取り除く。
surface finish of the die can be another
cause.

HOT TEARING/CRACKING Solidification

This defect is caused by metal shrinking ①Eliminate Extreme temperature difference of die （ eliminate the
Shrinkage Cracking solidification time lag of the thick part ）。 The die temperature is raised, and
during solidification while under tension. Due to solidification
At the last place to solidify a tear or the casting temperature is raised at times.
shrinkage crack occurs ②Make the chill time appropriate 。 in many cases it is made short.
crack develops which can be seen at the on the surface
surface ③The Appropriate quantity of die lubricant should be used. （ less in chilling places,in
(Not HOT SHORTNESS) overheating parts its made high ）
④The thickness of the part is made uniform 。
⑤Apply roundness to product corner parts and sharp edges 。
HOT SHORTENESS Hot crack ⑥The extremely thin part in product should be avoided 。 But the thickness
The composition of the alloy causes the 離型後高い応力がかか should be made appropriate.(not very thick or thin)
metal to be too weak at high っている spot の casting ⑦The metal spreading is made proper by changing the casting method 。
temperatures(after solidification). This surface に , 冷却時収縮 ⑧The alloy composition, impurities is made appropriate 。 Specially main
then can cause crack in the surface of 力に耐え切れずに生じた attention is give to the iron content.
the casting to appear in regions of high 割れ
stress when the casting cooling (and
contracting). NOTE:This defect can
occur in conjunction with hot cracking.

SINK Shrinkage ①The temperature of the metal mold and the casting temperature are
A sink is caused by a shrinkage cavity when delaying the metal lowered.
being near the surface of the casting. solidification on the die ②Apply appropriate quantity of die lubricant 。（ less in chilling places,in
This causes the surface of the casting overheating parts its made high ）
surface the shrinkage ③Avoid extreme changes in product thickness 。
to collapse into the cavity as occuring during this time
solidification occurs.Sinks are caused ④Apply roundness to product corner part & sharp edges 。
causes dent on the cast ⑤Impurities level in the alloy should be in appropriate quantity 。 In many
by the same things as shrinkage surface.
porosity as well as very poor thermal cases it is made less.
controle of the die because hot spots ⑥Die cast の熱中神泉が thickness の central part になるように , die
are required for sinks to form. temperature,product shape, metal flow velocity, adjust this conditions 。
SINK Shrinkage ①The temperature of the metal mold and the casting temperature are
A sink is caused by a shrinkage cavity when delaying the metal lowered.
being near the surface of the casting. solidification on the die ②Apply appropriate quantity of die lubricant 。（ less in chilling places,in
This causes the surface of the casting overheating parts its made high ）
surface the shrinkage ③Avoid extreme changes in product thickness 。
to collapse into the cavity as occuring during this time
solidification occurs.Sinks are caused ④Apply roundness to product corner part & sharp edges 。
causes dent on the cast ⑤Impurities level in the alloy should be in appropriate quantity 。 In many
by the same things as shrinkage surface.
porosity as well as very poor thermal cases it is made less.
controle of the die because hot spots ⑥Die cast の熱中神泉が thickness の central part になるように , die
are required for sinks to form. temperature,product shape, metal flow velocity, adjust this conditions 。
⑦To have proper metal flow the casting method is changed.
⑧To have proper metal flow the casting conditions are changed.

①The die surface temperature is lowered in general and chill time is increased.
EXPLODED METAL はぜ ②The filling condition (speed & high-speed stroke) is adjusted such that the flow of
MAIN CAUSE:A combination of blister （ふくれ）のは metal should not fall into disorder.
porosity and the casting being ejected ぜたもの ③ The position of spout &O/F is changed so that the metal flow is
before it has solidified completely.This
appropriate.Especially ample gas must be removed.
allows the trapped gasses to burst out ④The temperature of the metal mold, the shape of the product, the speed of the
of the casting along with any metal flow, and the state are adjusted so that there is no Over heat ing locally in
unsolidified metal. the metal mold. 　　　　　

WARPAGE そり（ Strain ①Chill time is made proper and the extrusion time is delayed.
A casting can deform after ejection ②The die temperature is evened up.
during the time it is cooling down to distortion ）
casting get distorted ③To make the uniformity of thickness, that is there must be gradual change in
room temperature.The root cause can the thickness 。
sometimes be the casting geometry or and the prescribed
shape is lost. ④The shape of the casting is examined, and shape is changed.
alloy specification. 　 Warping can be ⑤Reduce the time of too high casting pressure , to make the casting
minimised by ejection at a lowe ｒ　 temperature uniform coolant is used in the overheating places.
temperature. 　 Uneven die temperature
is a major cause of this type of defect.

SOLDERING Burn ①Die cooling , especially spout ingate,and overheated parts are locally cooled.
Chemical attack and bonding of on the die surface に ②Apply sufficient amount of suitable mold lubricant 。 Moreover, the metal mold is
aluminium to die steel.This causes metal が融着して出来 removed and polish 融着 is removed frequently.
aluminium to be torn away from the た product surface の ③Impurities, especially the iron content should be in appropriate level.
casting during ejection. ④Increase the thickness of the gate spout （ gate speed is slowed
Soldering can be reduced by a change down ） moreover,gate spout の direction やつけ方の improper を revise 。
in alloy and/or a reduction in ⑤Metal velocity is adjusted such that the cavitation does not rise.More think of
die/metal temperature. the product shape roundness degree 。

　
SHRINKAGE POROSITY Shrinkage Cavity ①Spout speed is increased, the filling time is shortened.
This defect is caused by metal reducing ②Time of increasing pressure is shortened.Raise the casting pressure 。
its volume during solidification and an ③Decrease cavity occuring part die temperature,and check the entire die cooling and cooling steps.
Hole generated inside ④In cavity occuring part core pin is added.
inability to feed shrinkage with more metal the casting after the
before solidification.Hot spots can also ⑤Cavity occurence part metal die material is checked.
Al is filled and ⑥Change the spout gate thickness,width, ＆ position.Change pouring,gas escape path size ＆ place.
cause shrinkage porosity to be solidifies.
concentrated in a specific zone.See ⑦Avoid sudden change in thickness 。 Make the thickness as uniform as possible.
'SINK'.

HEAT CHECKING Heat check wound ①The heat check on the surface of metal mold Cavity is removed immediately.
This defect is caused by the surface Cavity surface に heat ②The polish on the surface of the metal mold is made excellent, and marks etc. are neliminatedt.
of the tool steel continually expanding check を生じた金型を ③The metal mold cooling is done enough. Ample cooling of spout part and thick part must be done and overheating
& contracting during use.Excessively used case, 鋳肌にそれ should be avoided.
cold dies & die flexing accelerate this がそのまま写し出された ④The temperature difference of die temperature and casting temperature is made as low possible in view of
effect. きず avoiding the thermal shock.
⑤Examine the die material and heat treatment, and also high tensile ＆ compression strength .
⑥Preheat before doing casting 。 before quenching の trial では数多く鋳造しない。
⑦ Sprinkling water from die surface is avoided as much as possible.

LEAKER Pressure defect ①Eliminate 圧検部の misrun defect,gas run, cold shut external defect is lost 。
Causes of leaks in castings where when pressure is applied ②Eliminate 圧検部の shrinkage cavity, blow hole, oxide mixing inner defect .
pressure tightness is required can be in the casting leakage ③After examining the casting shape if necessary, change is made. 。
oxide folds and/or inclusions and/or occurs from the casting ④After Examining the material,if neccessary change.
porosity in conjunction with a surface part. ⑤After examining the alloy ingredients, impurity amount,if required maintained
defect which completes the path for a under the appropriate level .
leak.A close analysis of the leaking area ⑥A new casting process is adopted.
may reveal which of the man causes is
causing the leak.

DISCOLOURED SURFACE Cold shut 様 潤滑剤や lubrication amount is reduced 。

Oxide films(dross) and/or residues in Al runs along with the
the cavity and/or particles in the matal remains of the 潤滑剤 注． Cold shut 様でも塗装すれば湯模様不良となるがﾊﾞﾌをかければ
and/or excess die lube can cause or lubrication. 　　　消すことは可能。湯じわは消せない（著しく浅ければ可能）
the surface to be discoloured.And it can
be caused by a part of the die being too
cold causing the casting to have darker
regions or 'smears' on the surface.

BREAK OUT 破断ﾁﾙ層 ①Injection begins soon after the AL is poured into plunger.
Metal flakes(cold flakes)which get Before injection,hardened ②The temperature of the Metal is raised （ It helps in slow hardening ） .
caught in the gate during cavity fill can AL chips inside plunger ③To prevent dust pieces the gate shape is examined and if required it
break out unevenly when the casting is sleeve get blocked in the is changed.
trimmed. gate and obstructs AL
flow during injection.

EJECTOR DAMAGE Ejector pin Marks ①Oil or impurities sticking to the Melting raw materials is removed as
In broad terms, it can be defined as Depending on the ejector much as possible.
excessive pressure on the casting surfacepin dent marks in the ②Melted and treated AL,while transfering it to using metal do silently.
by the ejector pin(s) during ejection. product surface.
INCLUSIONS Foreign matter mixing ①The metal mold is cooled enough. Moreover,cool it locally.
The main causes of this type of defect Mixing of Foreign ②By increasing the casting cycle, product ejection time, ample solidification is done
are dirty/contaminated metal and/or substance in the casting. so that product ejection is done properly.
poor melt handling practice. ③To avoid Partly thick places , whether to change the shape or change the ejector
pin location. 　

EROSION/CAVITATION ①Ample cooling of spout(gate ), 溶湯の激突部 is done.

Erosion is caused by direct molten metal Erosion/ Cavitation
Depending on the use of ②The erosion part and the corrosion part of the metal mold are repaired.
impingment on die steel. Cavitation type ③The thickness of the spout(gate) is made suitable.
erosion is caused by turbulence which eroded metal die, wound
on the casting occurs. ④The position of the spout is changed.
causes low pressure regions in the ⑤The direction and use of spout are changed.
flowing metal.These low pressure regions
cause voids to form which can collapse
at the die surface & cause erosion.
EROSION/CAVITATION ①Ample cooling of spout(gate ), 溶湯の激突部 is done.
Erosion is caused by direct molten metal Erosion/ Cavitation
Depending on the use of ②The erosion part and the corrosion part of the metal mold are repaired.
impingment on die steel. Cavitation type ③The thickness of the spout(gate) is made suitable.
erosion is caused by turbulence which eroded metal die, wound
on the casting occurs. ④The position of the spout is changed.
causes low pressure regions in the ⑤The direction and use of spout are changed.
flowing metal.These low pressure regions
cause voids to form which can collapse
at the die surface & cause erosion.

CRACKED CASTING Crack ①Die temperature 　 chill time,ejection time are made proper.
A crack in the casting can be caused by During die opening, when ②Give ample draft angle for ejection, remove if there is any undercut.
mechanical damage when the die is the component is ③Do ample die surface polish and roundness is applied to the corner sharp edge part
opened or when the casting is ejected. ejected, the increased of the product.
This classification excludes HOT mechanical strength on ④The extrusion board moves in parallel and it extrudes it uniformly
CRACKING & POROSITY. Also the the product causes ⑤Ejector pin の strength が十部あるようにする。
definition excludes HOT SHORTNESS. crack. ⑥ 中子 , 型等のがたをなくし ,movement direction に parallel に move ようにする。
⑦Alloy composition,and impurities are made to appropriate level.
DEFECT TYPE MAIN CAUSES Defect Counter Measure
SHORT FILL
Phenomen
Misrun ①Raise the die and metal pouring temperature
MAIN CAUSES:Metal is frozen on
Defect ②reducing parting agent quantity and also sufficient air blow
before the cavity is filled or by melted AL ③increasing the sprue velocity, shortening the filling time
insufficient metal being ladled. solidifies ④shortening the 増圧
before filling ⑤increasing the 終圧
cavity volume.
⑥鋳造方案を検討し, change location and size of sprue.
⑦use sufficient gas escaping way
COLD SHUT cold shut ⑧die surfaceにshot blast
MAIN CAUSE:Metal is frozen when Melted AL が
two metal fronts join. merging spot に ⑨ Get changed product shape, thickness properly from the des
おいて fully
merge せず残し ⑩especially, in selective point make sure that thickness is not
た境目 ⑪choose alloy which has large solidification range.

湯じわについては above mentioned と similar でよいがよく problem となるので

scares ①raise die temp 。 For this reduce parting agent 。内例を絞る。
SCALING dissolve metal's
MAIN CAUSES:Layers of metal and 　外例を reduce 。 Fasten the cycle time 。 Completely stop wa
divided flow
oxides can be created by poor shot remainants 。
pattern if not
end controle and/or bad gate and ②proper gas escaping during casting must be done 。
merges properly
runner design. ③raise the high speed velocity 。
then slight wrinkle ④O/F addition, runner addition
occurs.

ふBlister ①generally if die surfac temperature is lowered then the chill time is
BLISTER(surface or subsurface くDepending on ②in order maintain the metal flow (without turbulence) the flow conidtions （
blow hole) れgas entrapped in high speed stroke) is adjusted 。
鋳the casting the ③The position of spout &O/F is changed so that the hot water flow is
MAIN CAUSE:Trapped gases are in suitable.especially gas escape out way should be used.
the casting when the die is opened 物swelling occurs ④metal temp,product shape, metal flow velocity, conditions are adjs
when the castingis still weak. This にon the cast that the selective points in die does not get overheated 。　　　
allows the conpressed gas to expand 含surface
and cause a blister. ま
FLASH れBurr ①The casting pressure is lowered.
バ
た from casting ② Time of increasing pressure is slowed down.
MAIN CAUSE:Metal pressure is too high upon
the projected surfacearea(facing the リ
ｶ product a bit of ③ He ﾞ Nt depth of the metal mold is examined and when it is t
plattens)of the casting at the end of cavity ﾞ AL comes out
鋳
fill.This creates a force across the parting line ｽwhich is of no
物 ④ The shooting speed is adjusted (Slow down).
which is too great for the clamping force of にuse,this occurs ⑤ Whether the metal mold is uniformly heated by using light is
the machine. The die is then forced apart
which allows metal to escape. よbecause of
生 and the trouble part is corrected.
りraised core or
じ
鋳core slide part
た
肌etc. 。
は
COLD FLAKES 上AL solidification
み
MAIN CAUSE:Metal is allowed to cool too much ①burning starts immediatley after pouring the Al in to
in the shot sleeve. The solid particles にprocess
出
are then injected into the cavity. These flakes し
生 inside plunger ②The temperature of the hot water is raised (to prev
are often clearly visible on the surface of the 不
じ sleeve solidified Al from harden).
casting with the nakid eye. たchips get mixed in
要 ③To prevent mixing, the wire net strainer is used in t
部
盛 the product laddle.
分
り
,上
SHOT LUBE STAIN Plunger oil
MAIN CAUSE:This defect occurs が ①use proper quantity of plunger sleeve oil （ reduce ）。
型
りif plunger sleeve Proper quantity is mentioned below 。
when too much shot (tip) lube is 割is more then
used. 　 350 ～ 800ton M/C 　　 3 ～ 5cc/ ｓｈｏｔ
りstain occurs in 　 1,250ton M/C 　　　　 5 ～ 8 ｃｃ / ｓｈｏｔ
面the surface
や
ｺ
ｱ ①change spout speed and filling time （ generally pouring fa
AIR POROSITY ｽBlow hole （ Gas
MAIN CAUSES:This defect is caused ② Shortening of time of increasing pressure. 。
ﾗhole ） ③An increase in casting pressure. 。
by trapped air in the casting which can gas generted
ｲair,parting agentfrom
come from several sources. It can be ④reduce the die parting agent applying quantity , next the k
ﾄand Al in side the die parting agent is changed.
caused by poor shot end controle,poor ﾞ die, solidifies inside
venting and over flow function or bad ⑤Do sufficient air blow 。
面 the casting and ⑥enlarge spout , 湯溜 , gas escape passageas well aschange of
gating and runner design. 等 creates big hole. position ,then change of die partition face 。
に ⑦Reducegas and oxide inside melted Al （ melted waste ・ oil are avoided a
発 as possible ）

DRAG MARKS 生scratch

すScratch wound ①while removing Die side wall surface under cut, do sufficient
MAIN CAUSE:Insufficient draft or an polishing 。
undercut causing a casting to be damaged on るcaused on
the surface when it is ejected.This effect may
②It is easy to polish the pull out inclination of the metal mold
be reduced by changing the temperature at
surface of the component pulling out direction .
which the casting is ejected.Poor surface casting when ③product part の deep carving こみをなくし , pull out slop as well ascorner p
finish of the die can be another cause. extruded from corner part の roundness を use sufficiently 。
die biting metal ④apply die parting agent ample 。 once again change to the suitable
mold parting agent （Ｓｉ -wax system is good ）。
⑤heat of die is removed 。 decrease the die surface
HOT TEARING/CRACKING temperature 。
MAIN CAUSE:This defect is caused by metal
solidification ①Eliminate⑥ 溶湯の金型溶湯の融着物を取り除く。
Extreme temperature difference of
shrinking during solidification while under shrinkage die （ eliminate the solidification time lag of the thick par
tension. At the last place to solidify a tear or cracking t ）。 The die temperature is raised, and the casting temperature
crack develops which can be seen at the Due to
surface(Not HOT SHORTNESS) is raised at times.
solidification ②Make the chill time appropriate 。 in many cases it is made
shrinkage crack short.
HOT SHORTENESS occurs on the ③The Appropriate quantity of die lubricant should be used. （ less in
hot crack
surface chilling places,in overheating parts its made high ）
MAIN CAUSE:The composition of the alloy 離型後高い応力
causes the metal to be too weak at high
がかかっている
④The thickness of the part is made uniform 。
temperatures(after solidification). This then can ⑤apply roundness toproduct corner part sharp edges 。
cause crack in the surface of the casting to spot の casting
⑥The extremely thin part in product should be avoided 。 But the
appear in regions of high stress when the casting surface に , 冷却 thickness should be made appropriate.(not very thick or thin)
cooling (and contracting). NOTE:This defect can 時収縮力に耐え
occur in conjunction with hot cracking. 切れずに生じた ⑦the metal spreading is made proper by changing the casting
割れ method 。
⑧the alloy composition, impuritiesis made appropriate 。 Specially ma
attention is give to the iron content.
 short.
HOT SHORTENESS ③The Appropriate quantity of die lubricant should be used. （ less in
hot crack chilling places,in overheating parts its made high ）
MAIN CAUSE:The composition of the alloy 離型後高い応力
causes the metal to be too weak at high
がかかっている
④The thickness of the part is made uniform 。
temperatures(after solidification). This then can ⑤apply roundness toproduct corner part sharp edges 。
cause crack in the surface of the casting to spot の casting
surface に , 冷却 ⑥The extremely thin part in product should be avoided 。 But the
appear in regions of high stress when the casting thickness should be made appropriate.(not very thick or thin)
cooling (and contracting). NOTE:This defect can 時収縮力に耐え
occur in conjunction with hot cracking. 切れずに生じた ⑦the metal spreading is made proper by changing the casting
割れ method 。
⑧the alloy
①The composition, impuritiesis
temperature made appropriate
of the metal mold and the。 Specially
casting ma
attentiontemperature
is give to theare
ironlowered.
content.
SINK shrinkage ②apply appropriate quantity of die parting agent 。（ less
chilling places,in overheating parts its made high ）
MAIN CAUSE:A sink is caused by a shrinkage when delaying
cavity being near the surface of the casting. ③Avoid extreme changes in product thickness 。
This causes the surface of the casting to
the metal ④apply roundness toproduct corner part sharp edges 。
collapse into the cavity as solidification solidification on ⑤Impurities in the alloy are made appropriate quantity 。 in m
occurs.Sinks are caused by the same things as the die cases it is made less.
shrinkage porosity as well as very poor thermal surfacethe ⑥die cast の熱中神泉が thickness の central part になるように
controle of the die because hot spots are shrinkage temperature,product shape, metal flow velocity, adjust this
required for sinks to form.
occuring during conditions 。
this time causes ⑦To have proper metal flow the casting method is chan
dent on thecast ⑧To have proper metal flow the casting conditions are
surface. changed.
EXPLODED METAL はぜ ①The die surface temperature is lowered in general and chill time
MAIN CAUSE:A combination of porosity blister （ふくれ） lengthened.
and the casting being ejected before it のはぜたもの ②The filling condition (speed & high-speed stroke) is adjusted such that t
flow of metal should not fall into disorder.
has solidified completely.This allows the ③ The position of spout &O/F is changed so that the hot water flow is
trapped gasses to burst out of the suitable.especially ample gas must be removed.
casting along with any unsolidified metal. ④The temperature of the metal mold, the shape of the product, th
speed of the hot water flow, and the state are adjusted so that the
no Over heat locally in the metal mold. 　　　　　
WARPAGE ①chill time is made proper and the extrusion time is delay
MAIN CAUSE:A casting can deform after ejection そり（ Strain
during the time it is cooling down to room distortion ） ②The die temperature is evened up.
temperature.The root cause can sometimes be ③to make the uniformity of thickness, that is there must be gra
the casting geometry or alloy specification. 　
casting get change in the thickness 。
Warping can be minimised by ejection at a lowe ｒ distorted and the ④The shape of the casting is examined, and shape is chan
　 temperature. 　 Uneven die temperature is a prescribed shape ⑤reduce the time of too high casting pressure , to make t
major cause of this type of defect. is lost. casting temperature uniform coolant is used in the overhe
places.
①die cooling , especially spout ingate,and locally cool the burned part.
SOLDERING burn ②Apply sufficinet amount of suitable mold lubricant 。 Moreover, the
MAIN CAUSE:Chemical attack and bonding of metal mold is removed and polish 融着 is removed frequently.
on the die
aluminium to die steel.This causes aluminium to ③Impurities,
surface に metal especially the iron content are made appropriate.
be torn away from the casting during ejection. ④increase the thickness of the gate spout （ gate speed is slowed down ）
Soldering can be reduced by a change in alloy が融着して出来 moreover,gate spout の direction やつけ方の improper を revise 。
and/or a reduction in die/metal temperature. た product
⑤Metal velocity is adjusted such that the cavitation does not rise.More
surface の
think of the product shape roundness degree 。

　
SHRINKAGE POROSITY shrinkage ①spout speed is increased, the filling time is shortened.
MAIN CAUSE:This defect is caused by metal cavity ②Time of increasing pressure is shortened.Raise the casting
reducing its volume during solidification and an pressure 。
inability to feed shrinkage with more metal ③decrease cavity occuring part die temperature,and check the
before solidification.Hot spots can also cause hole generated
shrinkage porosity to be concentrated in a inside the entire die cooling and cooling steps.
specific zone.See 'SINK'. casting after the ④In cavity occuring partcore pin is put up.
Al is filled and ⑤cavity occurence part metal die material is checked.
solidifies. ⑥change the spout gatethickness,width, ＆ position.change pouring,g
escape path size ＆ place.
HEAT CHECKING heat check ⑦avoid sudden change in thickness 。 Make the thickness as uniform
MAIN CAUSE:This defect is caused by wound possible.
the surface of the tool steel Cavity surface に
heat check を生 ①The heat check on the surface of metal mold Cavity is remo
continually expanding & contracting immediately.
during use.Excessively cold dies & die じた金型を used
case, 鋳肌にそれ ②The polish of the surface of the metal mold is made excellen
flexing accelerate this fffect. marks etc. are not left.
がそのまま写し ③The metal mold cooling is done enough. Ample cooling of spout part and t
出されたきず must be done and overheating should be avoided.
④the temperature difference of die temperatureand and casti
LEAKER Pressure temperature圧検部の
①eliminate is made as low possible
misrun in view
defect,gas of avoiding
run, cold the th
shut external
MAIN CAUSES:Causes of leaks in castings defect shock. is lost 。
defect
where pressure tightness is required can be ⑤examine the
②eliminate die material
圧検部の and heatcavity,
shrinkage treatment,
blowthe withoxide
hole, sufficiently
mixinghigh ten
inner
oxide folds and/or inclusions and/or porosity in when pressure is compression strength is used.
applied in the defect .
conjunction with a surface defect which ⑥Preheat
③After before doing
examining the casting
casting。 shape
before ifquching の trialchange
necessary では数多く鋳 is
completes the path for a leak.A close analysis of casting leakage い。
the leaking area may reveal which of the man occurs from the made. 。
⑦ Sprinkling
④After waterthe
Examining from die surface
material is avoided as much as pos
kind change.
causes is causing the leak. casting part.
⑤after examining the alloy ingredients, impurity amount,if
required it is made appropriate.
⑥A new casting process is adopted.
DISCOLOURED SURFACE cold shut 様 潤滑剤や lubrication amount is reduced 。
MAIN CAUSES:Oxide films(dross) and/or Al runs along
residues in the cavity and/or particles in the 注． Cold shut 様でも塗装すれば湯模様不良となるがﾊﾞﾌをかけ
matal and/or excess die lube can cause with the remains
the surface to be discoloured.And it can be of the 潤滑剤 れば
caused by a part of the die being too cold or lubrication. 　　　消すことは可能。湯じわは消せない（著しく浅ければ可能）
causing the casting to have darker regions or
'smears' on the surface.

BREAK OUT 破断ﾁﾙ層 ①Injection begins soon after the AL is poured into plunger.
MAIN CAUSES:Metal flakes(cold Before ②The temperature of the hot water is raised （ It helps in slow
flakes)which get caught in the gate injection,harden hardening ） .
during cavity fill can break out ed AL inside ③To prevent dust pieces the gate shape is examined and if
unevenly when the casting is trimmed. plunger required it is changed.
sleeve,during
injection get
blocked in the
gate and ①Oil or impurities sticking to the Melting raw materials is
INCLUSIONS Foreign removed as much as possible.
obstructs AL
MAIN CAUSES:The main causes of this matter
flow. ②Melted and treated AL,while transfering it to using metal do
type of defect are dirty/contaminated mixing silently.
metal and/or poor melt handling Mixing of
practice. Foreign
substance in
the casting.
 ①Oil or impurities sticking to the Melting raw materials is
INCLUSIONS Foreign removed as much as possible.
MAIN CAUSES:The main causes of this matter ②Melted and treated AL,while transfering it to using metal do
type of defect are dirty/contaminated mixing silently.
metal and/or poor melt handling Mixing of
practice. Foreign
substance in
the casting.
①The metal mold is cooled enough. Moreover, it cool locally.
EJECTOR DAMAGE Ejector pin ②By increase the casting cycle, product ejection time, ample
MAIN CAUSES:In broad terms, it can Marks solidification is done so that product ejection is done properly.
be defined as excessive pressure on Depending on ③to avoid Partly thick places whether to change the shape or chagne the
the casting surface by the ejector the ejector pin ejector pin location. 　
pin(s) during ejection. dent marks in
the product
surface.

EROSION/CAVITATION Erosion/ Cavitati ①Ample cooling of spout(gate ), 溶湯の激突部 is done.

MAIN CAUSES:Erosion is caused by direct on ②The erosion part and the corrosion part of the metal mold are
molten metal impingment on die steel. Depending on the repaired.
Cavitation type erosion is caused by turbulence use of eroded ③The thickness of the spout(gate) is made suitable.
which causes low pressure regions in the
flowing metal.These low pressure regions cause metal die, wound ④The position of the spout is changed.
voids to form which can collapse at the die on the casting ⑤he direction and how to apply the spout are changed.
surface & cause erosion. occurs.

CRACKED CASTING ①Die temperature 　 chill time,ejection time are made proper.
MAIN CAUSES:A crack in the casting can Crack ②Give ample draft angle for ejection, remove if there is any
be caused by mechanical damage when the During die undercut.
die is opened or when the casting is opening, when ③Do ample die surface polish and roundness is applied to the corner
ejected. This classification excludes HOT the component sharp edge part of the product.
CRACKING & POROSITY. Also the is ejected, the ④The extrusion board moves in parallel and it extrudes it
definition excludes HOT SHORTNESS. increased uniformly
mechanical ⑤ejector pin の strength が十部あるようにする。
strength on the ⑥ 中子 , 型等のがたをなくし ,movement direction に parallel に
product casuses move ようにする。
crack. ⑦Alloy composition,and impurities are made to appropriate lev
 Counter Measure
the die and metal pouring temperature。
ng parting agent quantity and also sufficient air blow
sing the sprue velocity, shortening the filling time
ning the 増圧 time.
sing the 終圧.
方案を検討し, change location and size of sprue.
fficient gas escaping way＆ユタまり。
faceにshot blast等かけ, die surfaceのdissolved metalのflowをalter。

hanged product shape, thickness properly from the design deptt.

ally, in selective point make sure that thickness is not very thin places.
e alloy which has large solidification range.

ついては above mentioned と similar でよいがよく problem となるので以下に特記する。

die temp 。 For this reduce parting agent 。内例を絞る。
reduce 。 Fasten the cycle time 。 Completely stop water
nts 。
r gas escaping during casting must be done 。
the high speed velocity 。
ddition, runner addition

lly if die surfac temperature is lowered then the chill time is increased.
maintain the metal flow (without turbulence) the flow conidtions （ speed ＆
d stroke) is adjusted 。
sition of spout &O/F is changed so that the hot water flow is
specially gas escape out way should be used.
temp,product shape, metal flow velocity, conditions are adjsuted, such
selective points in die does not get overheated 。　　　

sting pressure is lowered.

of increasing pressure is slowed down.
Nt depth of the metal mold is examined and when it is too deep, the meat height is corrected.
hooting speed is adjusted (Slow down).
her the metal mold is uniformly heated by using light is confirmed
trouble part is corrected.

①burning starts immediatley after pouring the Al in to plunger 。

②The temperature of the hot water is raised (to prevent AL
from harden).
③To prevent mixing, the wire net strainer is used in the metal
laddle.

use proper quantity of plunger sleeve oil （ reduce ）。

oper quantity is mentioned below 。
50 ～ 800ton M/C 　　 3 ～ 5cc/ ｓｈｏｔ
,250ton M/C 　　　　 5 ～ 8 ｃｃ / ｓｈｏｔ

nge spout speed and filling time （ generally pouring fast ）。

ortening of time of increasing pressure. 。
ncrease in casting pressure. 。
uce the die parting agent applying quantity , next the kind of
rting agent is changed.
sufficient air blow 。
rge spout , 湯溜 , gas escape passageas well aschange of
n ,then change of die partition face 。
cegas and oxide inside melted Al （ melted waste ・ oil are avoided as much
ible ）

removing Die side wall surface under cut, do sufficient

。
asy to polish the pull out inclination of the metal mold in
ponent pulling out direction .
t part の deep carving こみをなくし , pull out slop as well ascorner part,
t の roundness を use sufficiently 。
die parting agent ample 。 once again change to the suitable die
gent （Ｓｉ -wax system is good ）。
of die is removed 。 decrease the die surface
ture 。
の金型溶湯の融着物を取り除く。
te Extreme temperature difference of
minate the solidification time lag of the thick par
die temperature is raised, and the casting temperature
at times.
he chill time appropriate 。 in many cases it is made
propriate quantity of die lubricant should be used. （ less in
aces,in overheating parts its made high ）
ickness of the part is made uniform 。
oundness toproduct corner part sharp edges 。
remely thin part in product should be avoided 。 But the
should be made appropriate.(not very thick or thin)
tal spreading is made proper by changing the casting
。
y composition, impuritiesis made appropriate 。 Specially main
s give to the iron content.
 propriate quantity of die lubricant should be used. （ less in
aces,in overheating parts its made high ）
ickness of the part is made uniform 。
oundness toproduct corner part sharp edges 。
remely thin part in product should be avoided 。 But the
should be made appropriate.(not very thick or thin)
tal spreading is made proper by changing the casting
。
y composition,
①The impuritiesis
temperature made appropriate
of the metal mold and the。 Specially
casting main
s give to theare
mperature ironlowered.
content.
②apply appropriate quantity of die parting agent 。（ less in
illing places,in overheating parts its made high ）
Avoid extreme changes in product thickness 。
④apply roundness toproduct corner part sharp edges 。
⑤Impurities in the alloy are made appropriate quantity 。 in many
ses it is made less.
die cast の熱中神泉が thickness の central part になるように , die
mperature,product shape, metal flow velocity, adjust this
nditions 。
⑦To have proper metal flow the casting method is changed.
⑧To have proper metal flow the casting conditions are
hanged.
die surface temperature is lowered in general and chill time is
ned.
ling condition (speed & high-speed stroke) is adjusted such that the
metal should not fall into disorder.
position of spout &O/F is changed so that the hot water flow is
especially ample gas must be removed.
emperature of the metal mold, the shape of the product, the
f the hot water flow, and the state are adjusted so that there is
r heat locally in the metal mold. 　　　　　

hill time is made proper and the extrusion time is delayed.

he die temperature is evened up.
make the uniformity of thickness, that is there must be gradual
nge in the thickness 。
he shape of the casting is examined, and shape is changed.
educe the time of too high casting pressure , to make the
ting temperature uniform coolant is used in the overheating
es.
ally spout ingate,and locally cool the burned part.
mount of suitable mold lubricant 。 Moreover, the
d and polish 融着 is removed frequently.
ially the iron content are made appropriate.
ness of the gate spout （ gate speed is slowed down ）
の direction やつけ方の improper を revise 。
djusted such that the cavitation does not rise.More
shape roundness degree 。

speed is increased, the filling time is shortened.

of increasing pressure is shortened.Raise the casting
e。
ase cavity occuring part die temperature,and check the
ie cooling and cooling steps.
vity occuring partcore pin is put up.
y occurence part metal die material is checked.
e the spout gatethickness,width, ＆ position.change pouring,gas
path size ＆ place.
sudden change in thickness 。 Make the thickness as uniform as

eat check on the surface of metal mold Cavity is removed

tely.
olish of the surface of the metal mold is made excellent, and
etc. are not left.
tal mold cooling is done enough. Ample cooling of spout part and thick part
one and overheating should be avoided.
emperature difference of die temperatureand and casting
ture圧検部の
ate is made as low possible
misrun in view
defect,gas of avoiding
run, cold the thermal
shut external
s lost 。
etethe die material
圧検部の and heatcavity,
shrinkage treatment,
blowthe withoxide
hole, sufficiently
mixinghigh tensile ＆
inner
on strength is used.
at before doing
examining the casting
casting。 shape
before ifquching の trialchange
necessary では数多く鋳造しな
is
kling waterthe
Examining from die surface
material is avoided as much as possible.
kind change.
examining the alloy ingredients, impurity amount,if
it is made appropriate.
w casting process is adopted.
や lubrication amount is reduced 。

d shut 様でも塗装すれば湯模様不良となるがﾊﾞﾌをかけ

すことは可能。湯じわは消せない（著しく浅ければ可能）

n begins soon after the AL is poured into plunger.

mperature of the hot water is raised （ It helps in slow
）.
vent dust pieces the gate shape is examined and if
t is changed.

mpurities sticking to the Melting raw materials is

as much as possible.
and treated AL,while transfering it to using metal do
mpurities sticking to the Melting raw materials is
as much as possible.
and treated AL,while transfering it to using metal do

etal mold is cooled enough. Moreover, it cool locally.

ease the casting cycle, product ejection time, ample
on is done so that product ejection is done properly.
Partly thick places whether to change the shape or chagne the
location. 　

cooling of spout(gate ), 溶湯の激突部 is done.

osion part and the corrosion part of the metal mold are

ckness of the spout(gate) is made suitable.

sition of the spout is changed.
ction and how to apply the spout are changed.

mperature 　 chill time,ejection time are made proper.

mple draft angle for ejection, remove if there is any
t.
ple die surface polish and roundness is applied to the corner
e part of the product.
xtrusion board moves in parallel and it extrudes it
y
r pin の strength が十部あるようにする。
型等のがたをなくし ,movement direction に parallel に
うにする。
composition,and impurities are made to appropriate level.