Minimizing Porosity in Die Casting Parts. Die casting is popular method for machining metal parts for vehicles and electronics. When this method is applied, tough and well-detailed products are produced. However, due to large capital costs of the dies, die castings are preferred only for large scale operations. One important issue in this industry is the tracking of porosity in die casting parts.
In order to understand the concept of porosity in metal working, one must first understand the basics of die casting. Hot or molten metal is forcefully injected into a cavity, at pressures from 10 to 175 mPa. The cavity is then applied with that pressure until the metal freezes or solidifies. The mold cavity is made by two contacting parts: the cover half and the ejection half.
The pressure of injecting the molten metal results in high processing speed. It also induces uniformity, inside and out, of the finished product. However, air in the injection tube mixes with the molten metal during this speedy process. The trapped air bubbles in the product are called porosity in die casting parts. This is often considered a factory defect. If the bubbles are large or interconnected, they can cause loss of tensile strength in the final product.
There are several factors that affect porosity in die casting parts. The manufacturer must be sure that the molten metal is free from impurities and that the molds are clean. The working temperature of the furnace must also match with the metal being processes. Other factors include shot speed, lubrication and amount of pressure.
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