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Porosity in Die Castings
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
Kinetic Die Casting utilizes die casting to manufacture parts like aluminum car parts, airplane parts, lighting parts and much, much more. If you would like to request a quote, please visit our website:Die Casting quote
Posted in Die Casting Parts, newsletter
Tagged aluminum parts, die casting, newsletter, Porosity
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Kinetic Die Casting Company Monthly Newsletter
Kinetic Die Casting Company Monthly Newsletter Signup, our newsletter has three components:
1. Educational Topics (Money saving ideas)
2. Customer Success Stories / Customer tips
3. Kinetic Die Casting Company Updates (Discount of the Month)
Sign up to our monthly email newsletter using the box above. You will be able to safely unsubscribe anytime. Your email address will never be shared or sold
(See Privacy Statement).
This monthly email newsletter will give us a chance to send you information that is helpful to you and your company.
Some of the tips will save your company money by informing you of ways to take advantage of the benefits of die castings in our “Technical Education Topics Section”.
How to save money on die cast tooling and how to get the most from Kinetic Die Casting Company with the few manufacturing dollars you have to spend. You will receive some ideas from some of our customers that you may be able to use yourself.
Also there will be stories how inventors brought us their ideas and how we produced their products in our “Customer Success Stories” section.
Some of the Educational Topics will include:
# What is a die cast part?
# Compare Sand Casting to Die Casting
# What is draft angle, why is it needed?
# Why use different aluminum alloys?
Some of the Customer Success Stories / Customer tips will include:
# He wanted to bring melted chocolate to the world.
# He drove into my parking lot in a Pinto and out in a Mercedes Benze.
# They want to bring guitar music to the world.
# He proved aluminum die castings can be stronger than steel.
# He saved $139,000 by using aluminum die castings.
Some of the Kinetic Die Casting Company Updates will include:
# Discounts for purchases this month.
# Kinetic Die Casting Certifications and Approvals.
# What is new at Kinetic Die Casting.
If you have questions or newsletter suggestions, please give us a call 800-524-8083. You can also email us at sales@kineticdc.com.
Kinetic Die Casting can manufacture aluminum automobile parts, heat sinks, aerospace parts and much more. If you are looking for aluminum or zinc parts, visit our website Kinetic Die Casting Company
Customer Multiplied Total Sales 5x
About ten years ago, two men named “Brian” and “Ron” working for a machining company in Orange County, California contacted Kinetic Die Casting Company to quote a “Project” for a simple die casting tool to produce from 5,000 to 23,000 sets of parts.
Each set would make up a “Night Vision Goggle Device”.These sets consisted of seven (7) separate parts; the machining company would machine and assemble.
Brian needed these parts delivered very fast. The cost of the tooling needed to be inexpensive in order to be competitive.
We decided to make a “unit die tool” because of the low quantity potential and chose a good toolmaker in the Los Angeles area to make the tool. We opted to trim the parts with a simple “push through trim die” and to hand finish the parts. In order to make the tooling, we used 3D files from their Mastercam to produce IGES files. We added the shrinkage and draft necessary in order for the die casting tool to function properly.
The project went very well. In fact, Brian won additional contracts to produce more Night Vision Goggles. For a few years we were producing up to 5,000 sets or 35,000 parts every week. For three years straight this company was our top customer company and for five years a very good customer indeed.
At the project conclusion Kinetic Die Casting Company had produced over 400,000 sets of parts or 2,800,000 parts from that simple die casting tool for our good customer. This was a huge success for our customer because they grew in sales over 5x in those five years.
Drove a Ford Pinto in and a Mercedes Benz out
Before I started Kinetic Die Casting Company, in the early 80’s, “John” visited me at a different die casting company. He drove into my parking lot in a green Ford Pinto, about 10 years old. John was an interesting man, a magician who frequented magic clubs and visited Las Vegas on occasion. The most remarkable thing I remember about John other than his red hair was the gold nugget ring he wore.
John’s visit was regarding a new auto parts product idea. He told me that there was only one type of “Auto License Plate Frame” available. It was a flat plastic frame, in black or white typically, that was occasionally painted or had a sticker with the name of automobile dealerships (If you can remember, in the early 1980’s, he was right)
John had an idea for a new product. A license Plate Frame that was made of “metal” that look like gold and needed to look like gold nuggets “just like his gold nugget ring”. John pointed at the ring on his finger as he told me what he wanted. Seemed like a good idea to me so we proceeded to make the tooling for his “Gold Nugget License Plate Frame”. John sold several thousands of these frames and came to me with another idea.
John wanted a License Frame that looked like a “Silver or Gold Chain”. Within a year, John had other ideas for frames that I had made for him.
About a year and a half to two years after meeting John the first time, he drove his new Mercedez Benz to my office with the buyer of his license frame business. The buyer was a larger auto parts manufacturer. John made a lot of money on his ideas. His investment of a few thousand dollars for die casting tooling was well spent.
John, if you see this, please visit me and show me a few more card tricks.
Kinetic Die Casting manufactures products like heatsink die casting, aluminum housings, and lighting fixtures. If you would like more information, please visit our website:Kinetic Die Casting Company
