Download - Diecast Defects Manual
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 1
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 2
CLASSIFICATION OF DEFECTS
Surface defects or visual defects :
Cold shutCrackDragDamageChip offGate blow holeShrinkage. Heat sink markPeel offBlistersSoldering
Internal defects/ After machining defects
Blow holeInclusion
Pin hole porosityNon clearance.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 3
Cold shut
Intensifier not put on.Cycle time more.Less air spray.
Die Process
Water leakOverflow blocked.Vent blockedFlash from the die
MachineLower metal temperature.More die coat spray
Less die temperature.Dragging plunger tipLow / high first phase velocityLess/more velocity based on locationFlash from plunger tip..Fast shot start position.
Less jumping pressure.Less Accumulator pressure.Less / more biscuit thickness.N2 pressure ~ Acc pressure Shot not effective.
Man
Material
Low Si content.Un drossed metalMore diecoat dilution.High Fe content.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 4
Cold shut
DieWater leakOverflow blocked.Vent blockedFlash from the die
Crack in insert at water line area
Water line cut at ejector pin area
Coating leak from Auto sprayer
Water leak in injection rod
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 5
DieWater leakOverflow blocked.Vent blockedFlash from the die
Ejector pin broken at overflow area
Over flow gate blocked
Overflow catch up in previous shot
Cold shut
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 6
DieWater leakOverflow blocked.Vent blockedFlash from the die
Flash catch up at vent
Overflow catch up in previous shot
Cold shut
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 7
DieWater leakOverflow blocked.Vent blockedFlash from the die Die matching not proper.
Casting pressure exceeding M/C locking force.Chill vent area not matching.Die bulged.Die Insert is retracted or to the level of housing .Higher metal temperature.Worn out toggle link.Worn out platen shoe.
Cold shut
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 8
More Shot delay time.More Auto ladle waiting time .Auto ladle forward speed slow.Temperature indicator not working.Variation in topped metal temperature.Coil not working.No auto switch - on working.Cold auto ladle.
Cold shut
Process
Lower metal temperature.
Low / high first phase velocity
More die coat spray
Less die temperature.Dragging plunger tip
Less/more velocity based on locationFlash from plunger tip..Fast shot start position.
Loss at shot sleeve
Loss at furnace
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 9
Cold shut
Process
Lower metal temperature.More die coat spray
Less die temperature.Dragging plunger tipLow / high first phase velocityLess/more velocity based on locationFlash from plunger tip..Fast shot start position.
More spraying time.More Quantity of diecoat spray .Settling of die coat .
Time set morecatch up prone areaLess draft areaLess water cooling area
Leaking spray headMore no of nozzlesApplication of raw die coatto avoid catchup
Coat drain hole blockedSide core areaHorizontal land in die No effective air spray
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 10
Cold shut
Process
Lower metal temperature.More die coat spray
Less die temperature.Dragging plunger tipLow / high first phase velocityLess/more velocity based on locationFlash from plunger tip..Fast shot start position.
More water coolingMore die coat spray.Initial startup.
Waterline opened after stoppage
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 11
Cold shut
Process
Lower metal temperature.More die coat spray
Less die temperature.Dragging plunger tipLow / high first phase velocityLess/more velocity based on locationFlash from plunger tip..Fast shot start position.
Worn out plunger tip.Worn out shot sleeve.Less lubricant in plunger tip.Misalignment between plunger and injection .Mismatch between sprue bush and shot sleeve.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 12
Cold shut
Process
Lower metal temperature.More die coat spray
Less die temperature.Dragging plunger tipLow / high first phase velocityLess/more velocity based on locationFlash from plunger tip..Fast shot start position.
Set in wrong position
Valve getting loosened while runnimg.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 13
Cold shut
Process
Lower metal temperature.More die coat spray
Less die temperature.Dragging plunger tipLow / high first phase velocityLess/more velocity based on locationFlash from plunger tip..Fast shot start position.
Set in wrong position
Limit switch problem
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 14
Cold shut
Process
Lower metal temperature.More die coat spray
Less die temperature.Dragging plunger tipLow / high first phase velocityLess/more velocity based on locationFlash from plunger tip..Fast shot start position.
Wornout plunger tip
Wornout shot sleeve
Wornout sprue bush
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 15
Cold shut
Process
Lower metal temperature.More die coat spray
Less die temperature.Dragging plunger tipLow / high first phase velocityLess/more velocity based on locationFlash from plunger tip..Fast shot start position. Set wrongly
Poor response from limit switch
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 16
MachineLess jumping pressure.Less Accumulator pressure.Less / more biscuit thickness.N2 pressure ~ Acc pressure = 30 kg/cm 2
Shot not effective.
Low nitrogen pressure
Set value not as per standard
Cold shut
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 17
MachineLess jumping pressure.Less Accumulator pressure.Less / more biscuit thickness.N2 pressure ~ Acc pressure = 30 kg/cm 2
Shot not effective.
Cold shut
Refer PCM #
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 18
MachineLess jumping pressure.Less Accumulator pressure.Less / more biscuit thickness.N2 pressure ~ Acc pressure = 30 kg/cm 2
Shot not effective.
Cold shut
Auto ladle angle variationAl spill from auto ladleCold metal strucjk at nozzle of ladleLess or more intensification pressureLoss of Al due to flash from die.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 19
MachineLess jumping pressure.Less Accumulator pressure.Less / more biscuit thickness.N2 pressure ~ Acc pressure Shot not effective.
Cold shut
30 Kg/cm2 ( For eg : If Acc pr = 140 N2 pressure should be 110 Kg/cm2)
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 20
MachineLess jumping pressure.Less Accumulator pressure.Less / more biscuit thickness.N2 pressure ~ Acc pressure
Cold shut
Shot not effective. Oil in N2 cylinder.More intensification delay.Less second phase velocity.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 21
Crack
Die Process
Soldering in dieBend ejector plate
MachineHigher metal temperature.Less die coat spray
More die temperature.Biscuit catch up in plunger tipMore gate velocity Less/More dwell time
More jumping pressure.Improper machine platenalignment.Improper side core sliding.Die opening speed more. .
ManMaterial
Less diecoat dilution.Low Fe content.
Improper coating
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 22
Crack
DieSoldering in dieBend ejector plate
Fe content < 0.8 %No effective water coolingNear to gate .Less die coat spray.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 23
Crack
Process
Higher metal temperature.Less die coat spray
More die temperature.Biscuit catch up in plunger tipMore velocity based on location.Less/More dwell time
Temperature indicator not working.Variation in topped metal temperature.No auto switch - on working.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 24
Crack
Process
Higher metal temperature.Less die coat sprayMore die temperature.Biscuit catch up in plunger tipMore velocity based on location.Less/More dwell time
Less spray timeNo spray head nozzle focused to defectprone area. Inaccessible area to spray head.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 25
Crack
Process
Higher metal temperature.Less die coat spray
More die temperature.Biscuit catch up in plunger tipMore velocity based on location.Less/More dwell time
Near to gate area.No effective water coolingMore wall thickness area.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 26
Crack
Process
Higher metal temperature.Less die coat spray
More die temperature.Biscuit catch up in plunger tipMore gate velocity Less/More dwell time
No water cooling to plunger tip and sprue bushFlash in plunger tip.No forward stroke of plungerto push the biscuit.Length of the plunger tip less.Dragging in sprue bush.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 27
Crack
Process
Higher metal temperature.Less die coat spray
More die temperature.Biscuit catch up in plunger tipMore gate velocity Less/More dwell time
More second phase velocity.
Length of first phase velocity is below the gate.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 28
Crack
Process
Higher metal temperature.Less die coat spray
More die temperature.Biscuit catch up in plunger tipMore gate velocity Less/More dwell time More T2 timing setting.
More ejection time after die opening.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 29
Crack
MachineMore jumping pressure.
Improper machine platen alignment.
Improper side core sliding.
Die opening speed more.
Worn out Toggle linksWorn out platen shoes.Fixed die platen flexure.
Set value more
Worn out side core guide waysWorn out core pull rod
Valve setting more.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 30
Drag
Die Process
Soldering in dieRough surface after die polishingUnder cut in dieHeavy heat check marks
MachineHigher metal temperature.Less die coat spray
More die temperature.More gate velocity Less/More dwell time
More jumping pressure.Improper machine platenalignment.Die opening speed more. .
ManMaterial
Less diecoat dilution.Low Fe content.
Improper coating
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 31
Drag
Process
Higher metal temperature.Less die coat spray
More die temperature.More gate velocity Less/More dwell time
Temperature indicator not working.Variation in topped metal temperature.No auto switch - on working.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 32
Less spray timeNo spray head nozzle focused to defectprone area. Inaccessible area to spray head.
Drag
Process
Higher metal temperature.Less die coat sprayMore die temperature.More gate velocity Less/More dwell time
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 33
Drag
Process
Higher metal temperature.Less die coat spray
More die temperature.More gate velocity Less/More dwell time
Near to gate area.No effective water coolingMore wall thickness area.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 34
Drag
Process
Higher metal temperature.Less die coat spray
More die temperature.More gate velocity Less/More dwell time
More second phase velocity.
Length of first phase velocity is below the gate.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 35
Drag
Process
Higher metal temperature.Less die coat spray
More die temperature.More gate velocity Less/More dwell time More T2 timing setting.
More ejection time after die opening.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 36
Chip off
Die Process
Catch up in dieMatl projection in gate.
MachinePrefilling in Casting.
Low metal temperature.Ineffective shot
Cold metal from auto ladleMore breaking force
Biscuit catchup in sprue bush.Improper trimming. .
ManMaterial
Diecoat matl at gate. Improper handling of castings.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 37
DieCatch up in dieMatl projection in gate.
Chip off
Less die coat spray
Die chipped off
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 38
Process
Prefilling in Casting.
Low metal temperature.Ineffective shot
Cold metal from auto ladleMore breaking forceNo support in casting
Chip off
First phase velocity ends beyond the gateLow die temperature.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 39
Process
Prefilling in Casting.
Low metal temperature.Ineffective shot
Cold metal from auto ladleMore breaking force
Chip off
More shot delay timeMore autoladle waiting timenear shot sleeveOxide layer from furnace
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 40
Process
Prefilling in Casting.
Low metal temperature.Ineffective shot
Cold metal from auto ladleMore breaking force
Chip off
More weight hammer.Position of holding casting while breaking.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 41
ProcessPrefilling in Casting.
Low metal temperature.Ineffective shot
Cold metal from auto ladleMore breaking force
Chip off
More Shot delay time.More Auto ladle waiting time .Auto ladle forward speed slow.Temperature indicator not working.Variation in topped metal temperature.Coil not working.No auto switch - on working.Cold auto ladle.
Loss at shot sleeve
Loss at furnace
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 42
ProcessPrefilling in Casting.
Low metal temperature.Ineffective shot
Cold metal from auto ladleMore breaking force
Chip off
Oil in N2 cylinder.More intensification delay.Less second phase velocity.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 43
Chip off
MachineBiscuit catchup in sprue bush.Improper trimming.
No water cooling to plunger tip and sprue bushFlash in plunger tip.No forward stroke of plungerto push the biscuit.Length of the plunger tip less.Dragging in sprue bush.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 44
Chip off
MachineBiscuit catchup in sprue bush.Improper trimming No proper location for
Casting in trimming die.Improper alignment of trimming die.Bend trimming plate.Bulging in edge of the trimming pin.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 45
Material
Diecoat matl at gate.
Chip off
Less draftMore drag mark area.Prone to casting catch up.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 46
Peel off
Die Process
Flash from the dieLess die temperatureDie surface roughness
Machine
Oxide layer from metalShot blasting current .Shot blasting time.Flow marks .
Fast shot starts from gate.Improper gate velocity.
Intensifer action improperMore second phase velocityMore intensification delay.
.
ManMaterial
Less Cu content More die coat spray
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 47
Peel off
DieFlash from the dieLess die temperatureDie surface roughness
Die matching not proper.Casting pressure exceeding M/C locking force.Chill vent area not matching.Die bulged.Die Insert is retracted or to the level of housing .Higher metal temperature.Worn out toggle link.Worn out platen shoe.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 48
Peel off
DieFlash from the dieLess die temperatureDie surface roughness
More water coolingMore die coat spray.Initial startup.
Waterline opened after stoppage
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 49
Peel off
DieFlash from the dieLess die temperatureDie surface roughness Soldering in die
Die not serviced after taking corresponding shots.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 50
Peel off
Process
Oxide layer from metalShot blasting current .Shot blasting time.Flow marks .
Improper gate velocity.Fast shot starts from gate. S1 set value more
More first phase velocity.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 51
Peel off
Process
Oxide layer from metalShot blasting currentShot blasting time.Flow marks .
Improper gate velocity.Fast shot starts from gate.
Second phase velocityMore intensification pressureBlock in gate due to cold metal.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 52
Peel off
Process
Oxide layer from metalShot blasting current .Shot blasting time.Flow marks .
Improper gate velocity.Fast shot starts from gate.
Metal not cleaned properly
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 53
Peel off
Process
Oxide layer from metalShot blasting current .Shot blasting time.Flow marks .
Improper gate velocity.Fast shot starts from gate.
Less shots load to impellerFilter block.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 54
Peel off
Process
Oxide layer from metalShot blasting current .Shot blasting time.
Improper gate velocity.Fast shot starts from gate.
Set timing moreRe shot blasting
Flow marks .
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 55
Peel off
Process
Oxide layer from metalShot blasting current .Shot blasting time.
Improper gate velocity.Fast shot starts from gate.
Flow marks . Initial startup water line open
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 56
MachineIntensifer action improperMore second phase velocityMore intensification delay.
Peel off
Less N2 pressure
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 57
MachineIntensifer action improperMore second phase velocityMore intensification delay.
Peel off
Set value more
