Die Casting Tooling and Its Importance. Die casting tooling, otherwise known as dies, are typically prepared from alloy steel. The dies are finished from at least two sections to allow casting elimination. Due to the efficient approach of die casting …
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Tag Archives: Porosity
Porosity in Diecastings
What is Die Casting Porosity? (Die Casting Porosity) In order for you to know what die casting porosity is, you need to know the die casting basics. The most common form of Die Casting Porosity is a kind of factory defect in which die cast parts contain small pockets of void space and air within the metal, causing it to become porous.
Porosity in Die Casting is the air trapped by the metal inside the die casting parts. To know more, a basic knowledge of the die casting process is necessary. Die casting is a process wherein a particular amount of molten metal is put inside a shot cylinder, then it is applied (plunged) with great force with a piston so as to force the metal into a die cast mold or die cast die. During this “plunging process”, air inside the cylinder is forced along with the metal into the die casting mold. It is a very fluid turbulent process. The air forced into the mold with the metal and the metal already inside the mold is forced out of the mold through a series of gates, vents and overflows.
After this, the metal is left to cool down and harden or freeze inside the mold. The metal is then removed as a die cast part. The same process is repeated over again.
Die casting companies use metals which are non-ferrous, or do not contain Iron, as this is the highest factor for oxidation and rusting. Several examples of non-ferrous metals include zinc, aluminum, lead, Magnesium Die Casting, tin and copper. Kinetic Die Casting only uses aluminum die casting and zinc die casting.
In the worst case, die casting parts porosity, weakens die casting parts, if the voids or pockets are very large. Porosity typically matters most in pressure tight die casting parts. When the air escapes through a die casting part, it is typically caused by porosity.
The many forms of Die Casting Porosity are caused by many variables:
- Metal and Mold Temperatures
- Material Cleanliness
- Die Cast Mold Design
- Die Cast Part Design
- Die Casting Machine Pressures
- Die Casting Machine Shot Speed
- Die Casting Spray or Mold Release
- Other forms of porosity can be from “shrinkage” or wall thickness.
Employees of Kinetic Die Casting are POROSITY EXPERTS in die casting parts that need to be free of porosity.
Permalink: https://www.kineticdiecasting.com/kdc/porosity-in-diecastings/
Contact Kinetic Die Casting today if you need “solid” die casting parts.
Kinetic Die Casting, Inc.
6918 Beck Avenue
North Hollywood, California USA 91605
818-982-9200 telephone
818-982-0877 fax
Kinetic Die Casting manufactures custom metal parts to their customer. If you would like more information about Kinetic Die Casting, please visit our website:Kinetic Die Casting Company
Posted in Blogger, Die Casting Parts, Diecasting Process
Tagged #diecasting, #kineticdc, Die Casting Process, Porosity
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Kinetic Auto Parts
Kinetic Die Casting Company Makes Aluminum Auto Parts – A few months ago, an automotive parts customer contacted me; he makes aluminum hydraulic pumps for cars. He asked if he could move his die casting tooling inserts from his current die casting supplier to Kinetic Die Casting Company. He is getting over 50% leakage rejects from his current die casting supplier due to porosity. His product is prone to porosity because it has very thick material areas and very thin material areas. It would take a special effort to improve his production part process.
We gave him a price that was higher than he was currently paying and he agreed. What happened then was, he sent us his tooling inserts and we mounted his die casting inserts in our mold base and made his aluminum automotive pump parts. He was shocked at the difference. He had very few parts that leaked. We succeeded because we process every die casting job as a special job. Our single piece flow has also become single order flow.
I received this same request from that same customer this week, on a different part. He is also losing over 50% of his parts due to porosity leakage in his pumps. He now knows we can help him. The part cost is higher, but his total cost is much lower because he has fewer failures in his product.
Contact Kinetic Die Casting if you are getting bad products and we will help you.
Permalink: https://www.kineticdiecasting.com/kdc/kinetic-auto-parts/ ?
Posted in Aluminum Die Casting, Auto Parts, Blogger, Die Casting Parts, newsletter
Tagged #diecasting, #kineticdc, Aluminum Auto Parts, auto parts, Manufacturing, Porosity
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Diecasting Airplane Parts
Die Castings used for many Aircraft Parts. Demand for diecast airplane parts is increasing in the aircraft industry. Airplanes need lightweight materials for mobility. Moreover, planes require durability and resistance to several stresses while flying. Among metals, aluminum is used to serve as frames or skeletons of the aircraft.
In the aircraft industry, the strength of aluminum is significantly increased by high pressure die casting. Aluminum die castings used for airplane parts are strong against torsion and expansion stresses. These are important considerations since a flying aircraft is subjected to several forces.
In the machining process, there is always an associated imperfection called die casting porosity. This is the amount of gas that combines with the solidifying metal, as it cools in the mold. Porosity is characterized by the size and number of air bubbles inside the finished product. There are three levels of porosity. The second and third levels are unacceptable when it comes to machining airplane parts. This is to guarantee safety of the passengers.
Die castings used for airplane parts are usually made of different aluminum alloys. The two most common die casting alloys for aircraft parts are A380 and A413. For example, Al 7075 is commonly used for making frames because of its toughness.
Permalink: https://www.kineticdiecasting.com/kdc/diecasting-airplane-parts/
To get a price for aluminum die casting parts or die casting tooling, call toll free 800-524-8083 and ask for sales. Or email us at sales@kineticdc.com for a fast response on a price quote.
Kinetic Die Casting manufactures custom metal parts to their customer. If you would like more information about Kinetic Die Casting, please visit our website:Kinetic Die Casting Company
Porosity in the Die Casting Process
The steel die cavity is sprayed with a liquid release agent to prevent the molten metal from sticking to the steel cavity. Much like the cook will spray a pan before baking a cake. The spray dissipates into steam because the die is very hot. Porosity is natural in the Die Casting Process. The molten metal is squirted at a very fast speed and under extreme pressure into the die. It is like a running water hose with a thumb on the nozzle. The metal is moving very rapidly as it is forcibly injected into a steel die cavity, the metal picks up voids and air bubbles from the steam and the turbulence of the injection. The metal is squeezed into the die with a piston to evacuate or to remove and compress most of the voids and air pockets. Those voids and air pockets are called die casting porosity. It is a natural occurrence in the production of die casting parts. To read more about die casting porosity, review our web page: http://www.kineticdiecasting.com/porosity.html
Kinetic Die Casting Company 6918 Beck Avenue, North Hollywood, California 91605 USA
E-mail sales@kineticdc.com Toll Free: (800) 524-8083 Local: (818) 982-9200 Fax: (818) 982-0877
Permalink: https://www.kineticdiecasting.com/kdc/porosity-in-the-die-casting-process-2/
Kinetic Die Casting Company
E-mail sales@kineticdc.com / 818-982-9200 / 800-524-8083 Toll Free / 818-982-0877 Fax
6918 Beck Avenue, North Hollywood, California USA 91605,
Kineticdc makes:
Aluminum Heat Sinks
Automotive Die Casting Parts
Airplane Die Casting Parts
Light Fixture Die Casting Parts
Consumer Products Aluminum Parts
Aerospace Die Casting Parts
Military Die Casting Parts
Die Casting Tooling
Posted in Blogger, Customers, Diecasting Process, newsletter
Tagged #diecasting, #kineticdc, Die Casting Process, Manufacturing, Porosity
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Sources of Porosity in Die Castings
Sources of Porosity in Die Castings. The formation of bubbles in the castings results to die casting porosity. Porosity in die castings in defects caused by bubbles, often resulting from machine inefficiency, temperature variances, etc.
The following enumerates the most common sources of porosity in die castings.
Air Entrainment
Once air is trapped in the castings upon pouring of metallic substance into the die and the same air was not able to escape during solidification, a metal casting defect is expected to result from it. Both the temperature and the pressure directly affect the formation of such die casting porosity.
Blow Holes
When from a core, gas bubbles are blown into the liquefied metal, causing holes when solidified. This is also known as blisters.
Oxides
Some defects in die casting are caused by oxides. Oxide formation causes defects on the surface or in the subsurface of the die cast parts. In steel castings for example, the removal of inclusion material by blasting causes associated porosity. These are the grassy areas in steel castings.
Pinholes
Pinholes are characterized by the formation of tiny bubbles caused by less soluble gases. During solidification, soluble gases must dissolve upon combination with liquefied metal. Once insoluble gasses remain, defects such as pinholes will appear on the castings.
Shrinkage
Shrinkage normally occurs during solidification of liquid metal. An allowable degree of shrinkages is considered by die casting manufacturing companies. However when shrinkages goes beyond the allowable level forming a defective casting, this is considered a manufacturing cost. Die casting products are often deformed due to shrinkages in various forms.
This is the blog on the Kinetic Die Casting Company web site. KDC also writes about Porosity in Die Casting. Look at this website page for more details: www.kineticdiecasting.com/porosity.html. Contact Kinetic Die Casting Company at 818-982-9200 or email us at sales@kineticdc.com. Use this webpage to request “die casting part prices” www.kineticdiecasting.com/replyform.html
