Kinetic Die Casting Blog

There are many forms of Die Casting Porosity, many are caused by these die casting variables:

• Metal Temperatures and Mold Temperatures.
• Material Cleanliness.
• Die Casting Mold Design.
• Die Casting Part Design.
• Die Casting Machine Pressures.
• Die Casting Machine Shot Speed.
• Die Casting Spray or Die Casting Mold Release.
• Other forms of porosity can be from “shrinkage” or wall thickness.

What is 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, tin and copper. Kinetic Die Casting only uses aluminum and zinc.

In the worst case, porosity in die casting parts, 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.

Employees of Kinetic Die Casting are POROSITY EXPERTS in die casting parts that need to be free of porosity. http://www.kineticdiecasting.com/porosity.html

Die Casting Porosity Causes - Die casting is a method of forcing molten metallic materials, plastics and resins inside a molding machine and allowing it to cool down until it solidifies. The materials eventually acquire the shape of the mold. However, there are unsolicited finished products wherein the material contains air bubbles and void space inside the molded material. When this happens, the material becomes weaker and easier to break. This is why porous casts are often categorized as poorly made and of low quality. Die Casting Porosity causes the material to develop cracks, chinks and notches because of its unstable density. Porous materials are also usually made of low-class materials such as less cohesive and less pure resin and metal materials. Materials with thinner consistency tend to develop bubbles and air pockets within them when they harden. Fortunately, by following simple tips, you can avoid having air bubbles in your molded materials.

Have your molding machines checked up regularly for any cracks on the surface as these cracks can permit air to seep through the machine and cause bubbles within the material. Covering the molding surface with a sealant effectively reduces the occurrences of air bubbles. Try to use high-grade materials such as pure aluminum to assure that it is more dense compared to substandard and less-stable metallic substances. You can also opt to use vacuum devices to suck out the air as soon as the machine compresses the molten metal to remove any excess air which may cause bubbles inside. However, it is a bit more expensive than other machines, but investing on it will greatly reduce casting porosity.

How to remove diecast porosity - Die casting is a process in which a metal or resin of some sort is forced into a mold to take its shape. The amount of force it takes for the machine to push the molten substance is so great that the material becomes compact until it cools down and solidifies. This is usually used for toys, models, and other purposes such as costumes. However, one of the problems that die cast factory owners have to face is the occurrence of die cast porosity. This is an unwanted incident wherein the material becomes porous and has small pockets of air and space inside the material. This causes the material to become weak and frail. Studies show that porosity in diecasted materials is the leading cause of early deterioration.

Fortunately, there are several ways to reduce the incidence of die cast porosity in your product. If you are interested to know how to remove die cast porosity in your materials, here are a few tips you can follow.

First, you need to regularly check the die cast machine you are using to make sure that there are no crevices and cracks where air might come through during the molding. You can also smoothen out the surfaces of your mold and seal any chinks you can see. It is advised to use only substances of high quality, because substandard resins and metals tend to become bubbly and loose in consistency. Vacuum generating devices will also help to reduce air bubbles because the negative pressure will suck out all the air left inside the machine.

Tooling Changes to remove porosity. Die casting porosity is a type of factory output flaw wherein the products of die casting small to large air pockets inside the molded substance. Usually, the substances used for die casting are molten metallic substances, resins and thick plastics. When the consistency of the molten materials becomes too loose, the tendency for air bubble formation increases. Faulty machines such as cracks and chinks on the surface can also be the culprit for casting porosity as small amounts of air can leak inside the substance causing bubbles. Die cast porosity is considered to be a sign of low quality and substandard techniques used, because it causes the product to become weaker than those non-porous outputs. If you are wondering if there are any tooling changes to remove porosity, then you may need to consider these tips.

Holes which are found particularly in thicker regions of the castings may be caused due to the inadequacy of molten substance introduced in the machine. This causes porosity and exposure to air. It should be of adequate amount to lessen or eliminate the presence of air inside. You can also change your tools by cleaning and checking your casting machines. Smoothen it out and seal any cracks on the surface to prevent air from seeping inside the machine. Vacuum devices are also recommended as it largely diminishes the chances of air bubbles and porosity of your output as it sucks up the air that is present inside the mold. The negative pressure will also help in the molding of the substance. However, investing on vacuum devices are quite an expense, so you still need to consider your budget.

What is Die Casting Porosity? In order for you to know what die casting porosity is, you need to know the basics. Die casting is a process wherein a particular amount of molten metal is put inside a container, then it is applied with great force so as to force it into a mold. After this, the metal is left to cool down and harden then it is removed. 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, tin and copper.

What is die casting porosity? It is a kind of factory defect in which die casts contain small pockets of void space and air within the metal or plastic, causing it to become porous. Eventually, these air pockets cause the die casted material to become brittle and weak. Usually, die casting porosity is an unwanted result and is considered as a substandard product.

What causes die casting porosity? Basically, it is caused by poor handling and casting process. There might have been small cracks and crevices in the machine where the air could come in. The mixing process of the metal may have been poor, therefore creates bubbles inside the metal. One needs to check up the machine used for die casting regularly to prevent this kind of problem. It is also recommended to use vacuum devices to suck out the air inside the molten substance to reduce the incidence of die casting porosity.