Common Defects in Die Castings

Characteristics:

One part of the casting is misaligned with another part on the parting surface, resulting in relative displacement (for threads, this is called misalignment).

Causes:

• Displacement of mold inserts.

• Wear of mold guide components.

• Manufacturing errors in the inserts of the two mold halves.

Remedies:

• Adjust and tighten the inserts.

• Replace the guide pillars and bushings.

• Repair and eliminate the error.

Characteristics:

Overall deformation of the casting whose geometry does not conform to design requirements.

Causes:

• Poor casting structural design, causing uneven shrinkage.

• Premature mold opening, resulting in insufficient casting rigidity.

• Insufficient casting draft angle.

• Improper handling of castings.

• Improper placement of ejector pins.

Remedial Measures:

• Improve the casting structure to ensure uniform wall thickness.

• Determine the mold opening time and strengthen casting rigidity.

• Increase the casting draft angle.

• Handle castings carefully and gently.

• Use dedicated boxes for stacking castings, and use appropriate methods for removing gates.

• Some deformed castings can be repaired by [unspecified means].

Characteristics:

Scratches on the casting surface caused by impact.

Causes:

• Accidental damage during gate removal, cleaning, straightening, and handling.

Remedial Measures:

• Handle castings carefully; avoid stacking or impact during storage and transportation; use dedicated storage and transportation boxes.