DC SCHOOL TEXT BOOK
⑪ COUNTERMEASURE FOR
DC DEFECTIVE PRODUCTS
TOSHIBA MACHINE Co., Ltd.
DIE CAST MACHINE ENGINEERING DIV.
Ｐ－ 1
1. Misrun, Flow Line, Cold Shut
Flow Line: Molten metal doesn’t blend. Line on Surface
Cold Shut: Molten metal doesn’t blend.
Parting Surface (It occurs inside also.)
Misrun: Filling Shortage of Molten Metal to Cavity
It occurs because molten aluminium that injected in cavity doesn’t fill
before solidification, basically. The countermeasure shall be against
molten metal flow mainly.
Countermeasure for Defects by Selective Flowing Phenomenon
① Change of Gate Width, Position, Thickness Number
(It needs to be aware of flow speed at gate when gate width and thi
⑥ ⑤ ckness are changed.)
② Change of Gate Shape
③ Change of Cooling Water Position
④ Change of Runner Width, Thickness
①②
①② ⑤ Change of Air Vent Thickness, Cross Section
⑥ Add Overflow
④ ⑦ Shorten Filling Time, Intensify Time
(Don’t want to conduct as much as possible)
④
⑧ Increase Mold Temperature
⑨ Increase Molten Metal Temperature
(70)
⑩ Clear Gas Chamber
⑪ Change Type and Volume of Release Agent
Ｐ－ 2
2. Porosity, Blister, Leakage Including Porosity: Porosity that occurs when molten metal fill in mold. The
shape is round.
Including Porosity
Shrinkage Porosity: Porosity caused by contraction in volume when
aluminium alloy including air or gas of molten metal,
sleeve, cavity, plunger lubrication, and release agent
changes from liquid to solid.
Blister: Blister occurs by pushing up surface with internal pressure
of including porosity.
Leakage: It Is leakage of airtight products, and it occurs when
porosity or cold shut lead to outside.
Internal defects of product include blow hole, shrinkage porosity, inclusion of
solidified pieces.
50μ ｍ There are some problem cases by occurring of blow hole: when it occurs on cutting
Shrinkage Porosity
surface, when blister occurs by quenching treatment, and when occurring is limited by
x-ray transmission of strength parts etc.
When blow hole is looked in close-up, there are small blow holes freckled. If blow
hole doesn’t occur in round shape by roughened up the structure, it becomes almost
shrinkage porosity, and pressure leak occurs.
This pressure leak appears as a large difference of defective ratio for a die cast
machine with low intensify property.
Ｐ－ 3
Low Speed Rate The major cause of blow hole is gas inclusion at high speed filling by bad exhausting.
① Low Speed Acceleration The freckled level becomes higher, it is viewed with suspicion. This is not limited only
(Shock Less) Start Wave
thick wall area, it also occurs on entire cavity. Of course, large blow hole occurs on
thick wall area, however shrinkage also occurs at the same time. It will be explained
Time later.
Appropriate High speed filling method is beside the question for products given solution treatment
Low Speed Acceleration
(heat treatment), and this problem is difficult to solve even as laminar flow (4 ~ 5m/sec).
① Chip To reduce occurring of blow hole, it is effective to create a gate system to release gas as
much as possible.
Countermeasure Viewed in Causes
① Low speed startup shall be smooth without start shock to specified low speed rate.
And also there shall not be initial wave on molten metal in sleeve.
④ If there are a lot of wave, adjust N11 valve.
② It is better to use water-soluble than oil-based for plunger lubrication.
(Lubrication oil shall be a little as much as possible.)
③ It is better to be high in sleeve filling ratio as much as possible.
② ④ Moisture of release agent shall not be remained.
③ Target of Sleeve Fitting Ratio 20 ~ 50%
Ｐ－ 4
Shape of Overflow and Gas Release
Aluminium Alloy (Reference of Cold)
Countermeasure as Removing
A 15.0 ~ 35.0mm
① Cross section of air vent is better to be larger, and it shall be aware of the
B 0.5 ~ 1.2mm
thickness especially.
C 3.5 ~ 6.0mm
D 0.5 ~ 1.5mm (Change the thickness depends on the filling time.)
E 0.1 ~ 0.2mm
② It needs to careful thickness and cross section shape of overflow gate.
F 6.0 ~ 25.0mm
③ Air vent is not only for product area. It also shall be set on runner for low
G 15.0 ~ 50.0mm
H 10.0 ~ 40.0mm speed filling to decrease internal pressure of cavity.
④ Apply reducing pressure casting method.
③ ②
A
⑤ Apply a chill vent that is able to ensure maximum cross section of air vent.
①
⑥ Shrinkage porosity occur on thick wall where molten metal is stagnant.
Molten metal solidify and shrink on low temperature side on this portion
B C D E
where to stop supplying molten metal, and it appears as large porosities.
③ ② ⑤
F G H
Ｐ－ 5
Local Pressurizing Die Casting Method
Countermeasure by Specific Die Casting Method
Good Product
Product This problem is pointed out by pressure leak of pressure parts or X-ray
transmission of strength parts.
It is the only way to take the same countermeasure as for blow hole generally. The
largest cause is shortage of molten metal supply. It needs to be considered product
Squeeze Cylinder shape and wall thickness to resolve this problem. However this countermeasure
Pressure Pin is not allowed to take for most product actually, and it is also the cause that makes
difficult to solve this problem.
Vacuum Die Casting Method Vacuum Impregnation treatment is countermeasure for this problem but it seems local
Valve pressurizing method or vacuum casting method is applied recently because the
cost for equipments and impregnation agent is high. There is also super high
speed injection method as other countermeasure.
Local pressurizing method is very effective for a problem of the size of porosity
Vacuum however it is not said a stable countermeasure for pressure leak.
Tank
This cause is that blow hole and shrinkage porosity occur on the same place.
The aluminium this area shall be near solid, not melting.
Vacuum Pump Mold It is considered that gas is just compressed and form laminae or close to this
condition even porosities have disappeared visually. Therefore, temperature at
Super High Speed Injection Method 0.5mm
filling is very important for countermeasure against pressure leak by local
２ m/sec ４ m/sec ６ m/sec pressurization. It needs to increase sleeve filling ratio as much as possible to
satisfy this.
Conversional Super High Speed
(Fine Diffusion) Ｐ－ 6
3. Crack
Crack: Crack that occur on product.
The major cause of crack is stress difference of solidification shrinkage. It is si
gnificant when it occurs with internal defects that lead to external shrinkage o
r with cold shut etc.
If it is not enough as countermeasure by gate system, material change to stret
ch (ADC12 → AD10) is also effective.
Crack of solidification shrinkage cause drop of overflow at casting start of low
temperature mold, and they often appear on parting surface of product and ru
nner. For this type of phenomena, it is possible to measure temporally by mak
ing curing timer short 1 ~ 2sec. The gate system shall prevent contractive forc
e because it disturb auto operation cycle.
It also occurs when it result in large differences of wall thickness or mold temp
erature. It needs to be careful of cooling system.
4. External Shrinkage
External Shrinkage: Dent that occur on surface where shrank at last. When th
is phenomena appear inside, it is called shrinkage porosity.
Molten metal shall be solidify before the surface shrink. Mold cooling shall be
even. It is required to improve for enough supplying of molten metal.
The cause is internal defects. Refer to countermeasure for internal defects.
The rate of this problem occurrence increase when materials with more or les
s Si than 12% are used generally.
Ｐ－ 7
HDD (Hard Disk Drive)
5. Soldering
Soldering: The condition that molten metal adhere mold.
There is unevenness of micro level when polished mold surface is looked
with enlarged. These accelerate soldering (adhesion) and are one of cau
ses to make mold release difficult. When unevenness on the surface that
finished in micro level (10-3) is compared with the one that finished with (
10-6) of Al atom, it is equivalent to occur 1000M of obstruction for Al ato
m.
The filling for difference between these obstacles and lubrication effect a
High Speed Injection Before Gate
re given by release agent. However release agent could be rinsed away b
Monitor Data y turbulence of molten metal, and a few micro membrane is peeled.
Low Speed Rate: 0.55m/s Chemical reaction rate becomes twice by every 10 ˚C increasing generally
High Speed Range: 100mm . It is considered that pins with insufficient cooling and walls where touc
High Speed Acceleration: 5ms
h molten metal directly have soldering by chemical reaction (3Al + Fe →
High Speed Rate: 3.4m/s
FeAl3).
Speed Reduction Time: 15ms
Speed Reduction Rate: 0.55m/s It is sometimes possible to bring together different type alloys by friction
Intensify Time: 50ms welding. It requires more than 50MPa (500kg/cm 2) of welding pressure f
Casting Pressure: 80MPa or Fe and Al. It's just conceivable that this phenomena occurs at 50MPa
~ 120MPa of general casting pressure when sliding occur on contact surf
This condition is effective for products required short
ace of molten aluminium and mold while solidification.
filling time, thin wall, emphasis on appearance, and
multi cavity mold.
Be careful of soldering.
Ｐ－ 8
General Countermeasure for Soldering
Reduce plunger speed.
Lower molten metal temperature.
Reduce casting pressure.
As particular case, soldering often appear on overflow where is back side of molten
metal flow direction. Overflow area become also collect gas. This gas pushed on the
wall and compressed rapidly. The temperature of compressed gas become higher and
reduce thermal conductivity between aluminium and mold severely.
It is said that chill layer is formed on product surface with 1000˚C/sec of cooling
speed, but it is difficult to form complete chill layer on such area and the mold surface
becomes like being sprinkled powder. Soldering occur on aluminium castings as
plucked when this condition progresses. It is required to remove them as much as
possible to prevent soldering.
If gas on surface is prevented, it will be expected more effect. There is another
Structure of Chill Layer preventing method by surface treatment. This surface treatment (nitriding) prevent
soldering by increasing of high temperature hardness of surface of mold major
materials and inactivation of mold surface. Surface treatment makes mold surface
rough. Be careful where the draft angle is small.
Surface Chill Layer
Ｐ－ 9
6. Peel-Off, Thin Skin
Peel-Off, Thin Skin: A part of surface is peeled off thinly.
Peel-Off : There is other type of peel-off that occur on machining surface.
When blister area peeled off as thin skin like aluminium foil, the cause is mos
tly gas inclusion. Countermeasure for gas inclusion shall be referred. It is im
portant to air-blow by spray because mold moisture is also a cause of porosit
y near mold surface.
When shrinkage and pressurizing timing is of as local pressurizing method,
molten metal get in the crack of shrinkage and sometimes thick skin is create
d. In this case, the timing shall be adjusted. Therefore, surface peeling is co
nsidered also caused by molten metal penetration related to shrinkage. It is
effective to take a countermeasure for shrinkage. It is considered that peelin
g related to shrinkage occur where is solidified slowly: near thick wall or hard
-to-cooling area.
When molten metal get In cavity by vacuum device, the molten metal someti
mes peel off. In this case, the timing of vacuum shall be adjusted.
7. Breaking Solidified Piece
Most of solidified pieces are occurred in sleeve. It makes big difference of oc
currence depends on pouring time to sleeve, sleeve filling ratio, etc.
Important security parts have been produced as die cast method with the pr
ogress of weight saving of automobile parts. However the problem of solidifi
ed pieces is difficult to solved for general die cast method because of filling s
troke and reduction of sleeve filling ratio. A solution by high speed filling met
hod is clearly difficult also in applied materials that have heat treatment effe
cts by solution treatment.
There is another countermeasure to pre-heat sleeve by heater or oil as a cou
ntermeasure for solidified pieces. The effect has been shown by changing sl
eeve to insulated one.
Ｐ－ 10
8. Burr
It is considered that there are reasons of mechanical, mold, and pow
er of casting pressure and mold clamp mainly for burr.
1. Mechanical
① No loose on tie bar nut.
② No loose on mounting bolt for nut gear cover (LH side).
It seems there are no mechanical problems if above two items are sat
isfied and mold parallelism (0.1500) is achieved.
2. Mold
Here is an example of burr caused by mold problem.
① Burr occurrence and remaining inside mold
② ① ② Protruberance of ejector pin from parting surface
Mold Parallelism ③ Bias load at mold clamp because holding mold is not in center.
(0.1/500)
3. Relation of Casting Pressure and Mold Clamp Power
When die cast machine is selected, or die cast machine has already s
elected and mold is selected, it is required to determine if selected di
e cast machine or mold is adopted.
Casting pressure and mold clamp power need to keep below relation
as actual casting besides mounting relation such as size of die cast m
achine and mold.
Mold Clamp Power ＞ Casting Pressure × Casting Area
※ Injection power to open mold is exerted in a flash at injecting. Bur
r occur when mold open power ＞ mold clamp power.
※ Set it less than maximum casting pressure(Pm MAX).
Final check shall be conducted by reading load meter at casting. 5%
Up of Load Meter at Mold Clamp ＞ Load Meter at Injection
Ｐ－ 11
Conventional Control
③ Casting Pressure
When the filling is completed with 3.3m/s, burr
occur.
(1) Casting Pressure
Intensify Cylinder
Cross Section
Casting Pressure = × Accumulator Pressure × 0.9
Chip Cross Section
Accumulator Pressure Drop
(2) Intensify Time
Intensify Time = 0.01 × Wall Thickness (tm) × Wall Thickness (tm)
(3) Injection Power
Injection Power = Casting Pressure × Projected Area
(4) Mold Limit Casting Pressure
Mold Clamp Power
Mold Limit Casting Pressure =
Project Area
Servo Injection Control
When the filling is conducted with 3.3m/s and the speed
is reduced to 2m/s before filling completed,
no burr occur. ダ営技
※ Reducing speed rate can be set randomly. 05.01.11
渡 辺
Ｐ－ 12
Ｐ－ 13
