7 Common Die-Casting Errors and How to Avoid Them

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Are you in the die-casting products business?

With the growing demand for lightweight, high-performance components, the global die casting market will reach $94 billion by 2025.

As automotive, electronics, and telecommunications industries rely on die-casting, high-quality output is essential. One way of ensuring quality is to avoid the most common mistakes in the die-casting process.

Continue reading below for seven common die-casting errors and how you can avoid them.

  1. Using the Wrong Adhesive

One of the most common die-casting errors is using the wrong type of adhesive. Some die-cast manufacturers use cheap pressure-sensitive adhesive (PSA) to save on cost. The problem is they don’t match their die-cast products.

When choosing a PSA, check if it perfectly matches your specific application. Consider the adhesion, temperature, strength, and life expectancy of the PSA. These factors will ensure the PSA sticks to the seal and the mounting surface.

Click here for the benefits of hot foil stamping and how it promotes even heat transfer.

  1. Failing to Mix or Dilute the Bath

Using the best die-casting machine doesn’t guarantee the perfection of the output. Sometimes, failing to mix or dilute the galvanic bath can cause burnings or brown spots on the product.

Avoid this by diluting the solution with electrolytes. Alternatively, you may periodically change the bath mix.

  1. Using Improper Drafts

Before the casting process, the materials get stuck in the mold without proper drafts. Before casting, make sure the drafts start from the parting line.

Check the position of the drafts. Once you begin casting, its placement will affect the outcome.

  1. Not Using Enough Clamping Force

Using inadequate clamping force will result in metal splatters. Proper clamping ensures the injected molten stays within the two sides.

Test your machine and check the sides of the die-cast products. Make adjustments on the clamping force until the sides and edges are no longer messy.

  1. Failing to Check Harmful Elements

Harmful elements may enter the die-casting system and cause cracks in the casting. If the level of harmful impurities is high, they can reduce the alloy matrix’s plasticity.

Check for any harmful impurities when correcting alloy elements. Do this during the smelting process.

  1. Neglecting Better Finishing

Some manufacturers fail to design for better finishing. Finishing helps attain the final look of your product since it’s the last step in the die-casting process.

Consider the finishing in your design process. Create different finishing designs and pick the best one for your product.

  1. Poor Reporting

Without a proper reporting system, you’ll repeat the same production mistakes. Create a scrap reporting system showing vital details about the production process. The report should indicate the type of defect, the part number, the die, the shift, the operator, and the machine involved.

Go Beyond Avoiding Die-Casting Errors Now

By avoiding these common die-casting errors, you can increase your production without compromising quality. However, avoiding production mistakes is only one way of making a business more profitable.

Do you need more helpful guides? Learn about other techniques and strategies through our different articles today.

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