EASTERN ALLOYS, INC.

PO BOX Q MAYBROOK, NEW YORK 12543-0316 (914) 427-2151

TELEFAX (914) 427-5185

DIECASTING DEFECTS: IDENTIFICATION - - CAUSES & CURES

by
Derek Cocks, Mgr. Customer Engineering Services

STEP 1:

USING PROCESS CONTROL TO PREVENT DEFECTS:

“Prevention is always better than cure”, therefore, process control techniques are important.
Understanding the process variables is also the first step to both diagnosis and cure of defects.

Set-up sheets:

Have a set-up sheet available for each job - preferably covered in plastic and attached to the
machine. If defects start to appear don’t try to diagnose at this stage, check the machine settings
against the set-up sheet.

The Design of the set-up sheet is important and should follow the following basic rules:

l Keep it simple - one side of an 8 l/2 x 11” page.

l Group the information for setters, quality inspector, time study, etc.
l Use term which are understood in your plant. e.g., “bottle pressure” or “line pressure” or “top
pressure”, etc.

*A sample set-upp sheet is attached.*

Gauges:

Ensure that all gauges are present, are working and can be easily read. A 2 inch diameter
pressure gauge with a dirty dial twelve feet up on top of the accumulator cannot be read.

Valves and switch positions should have marked scales so that they can be set without having to
find a tape measure or count turns of valves.

SPECIALISTS IN THE ALLOYING AND REFINING OF ZINC ALLOYS EAZALL®

 EASTERN ALLOYS, INC.

Training:

Don’t assume that because the data is on the set-up sheet the personnel know how to set the
values. Have training sessions between engineering and setters, to ensure:

l Both parties know which control is being referred to.

l You know where the controls and gauges are on the machine.
l You know how to adjust it, and what its particular “quirks” are.
l Improvements to both set-up cards and machine controls can be made.

*A sample quiz sheet is attached.*

Measuring Equipment:

Every setter should have a small portable pyrometer with an immersion probe (for metal
temperature, etc.) and a surface contact thermocouple for measuring die temperature. One per
shop is not enough.

Serious consideration should be given to the purchase of shot monitoring equipment. It is

expensive and requires skill to use, but the pay-back time is short.

Tie bar load gauges should be fitted and working, if the machining has provision for them.
QUIZ SHEET:
Identify each gauge or control and enter details from set-up sheet.

SET-UP CARD COMPT. NO.

 EASTERN ALLOYS, INC.

STEP 2:

QUALITY CONTROL PROCEDURES TO SPECIFY AND IDENTIFY DEFECTS:

All castings contain defects -- it is essential to specify

what is acceptable and what is not. Good quality control
procedures will give early warning of problems.

Specifying Quality Levels:

Do not try to diagnose the cause of the defect at this stage.

Concentrate on saying:

Where it is on the casting. (eg., surface near the gate)

What it looks like. (eg., rough shiny marks)
HOW bad it is - difficult to quantify.
It is almost impossible to quantify any defect. The best you can
do is to have a sample available of the worst acceptable condition.
Use photographs or Xerox prints or computer stored pictures of
surfaces. Cut sections or reference radiographs may be useful for
internal defects.

Do not specify weight or density - this is frequently misleading.

Proof testing:

If possible devise a simple proof test which mimics the service

conditions, eg.:

Break test using a torque wrench or weight.

Pressure test for leakage.
Polishing test for cosmetic surfaces, using polishing
equipment, bright lights and a trained examiner.

Metallurgical Examination:

Radiography and machining tests require great technical skill and

are more appropriate for defect diagnosis than as practical quality
control techniques. At best they are subjective, since it is not
easy to put a numerate value on the results. At worst they can be
totally misleading, for instance a machined surface may show no
defects in a very porous casting since the pores lie 0.002 inches
below the machined face in that particular casting. A radiograph
may show only slight "shadows" which are in fact very tight cracks
which will seriously weaken the casting.
 EASTERN ALLOYS, INC.

Process Control Parameters:

The Quality department should preferably concentrate on checking

process conditions and relating these to the type of defects found.

Defects are related to the "primary process variables", ie. what

happens in the die, which in turn are controlled by the process
settings. Relationships are complex and care must be used but the
following guide lines may prove useful.

Process Variable Related Defects

Metal analysis All

Metal temperature All

Cavity fill time Cold shuts, dimensions

Gate velocity during fill Porosity, blisters,

soldering, erosion

Die face temperature Cold shuts, soldering,

cracks, dimensions

Lubricant-dilution quantity Porosity, blisters,

and spray pattern soldering

Knowing the process variables is the first-stage of defect

diagnosis.

The following values should be measured (since equipment is not

expensive):

Metal analysis
Metal temperature
Die face temperature
Lubricant - dilution and quantity

Cavity fill time

Gate velocity
Final metal pressure
 DETERMINING CAVITY FILL CONDITIONS

BY MEASUREMENT: If shot monitoring equipment is available the average

plunger speed during fill can be used to calculate gate velocity 'V'
and cavity fill time 't' as shown below:

Plunger speed during fill = 40 ips

Plunger diameter = 3.0 in. diam. = 7.07 sq.in.
Gate area = 0.02 x 10 in. = 0.20 sq.in.
Casting weight = 1.25 lb. = 5.43 cu.in.
Gate Velocity ‘V’ = 40 x 7.07
0.2 = 1404 i.p.S. or 117 f.P.S.

Cavity fill time 't' = 5.43 = 0.0192 secs. or 19.2 millisecs.

7.07 x 40

BY PQ2 - NADCA "FLOW PREDICTOR":

Use either manual or computer systems to predict values of 'V' and 't'.
Machine performance data may either be measured as above or
manufacturer's data. Accuracy is usually ± 10%.

l Step 1
Graph the machine shot-end capability by putting two values
on the graph supplied.

F l o w R a t e Q

l Step 2 Gate Area

Choose a transparent resistance graph for the metal being cast.

F l o w R a t e Q

l Steps 3-6
Put the two together and take readings, then make three
simple calculations.

Note: This is analogous to putting the die on the machine.

• Steps 7-6
Fill in readings on the worksheet table and compare values.
This gives fill conditions for a range of gate areas and is PLUNGER DIAMETER = 3.00 IN.
analogous lo carrying out several die trials. HYDRAULIC PRESSURE = 1200 PSI
SHOT SPEED CONTRO L = 100 %

GATE AREA (A) SQ. IN. GATE VELOCITY (V) FPS FILL TIME (T) MS
0.100 121 37.3
0.150 120 25.3
I - - - - - 0.200 ---------------- 117 - - - - - - - - - - - - - - - - - - - - 19.3 ----I
I - - - - - 0.260 ---------------- 114 ------------------- 15.9 ----I
I - - - - - 0.300 ---------------- 111 ------------------ 13.6 ----I
I - - - - - 0.350 ---------------- 107 ----------------- 12.0 ----I
I - - - - - 0.400 ---------------- 104 ---------------- 10.9 ----I
I - - - - - 0.450 ----------------- 100 ---------------- 10.1 ----I
0.500 96 9.4
 EASTERN ALLOYS, INC.

Process Control "Windows":

Usually there is a range of values, within which good castings are

produced. Often several process variables are related, thus a
"control window" can he specified.

The attached graph shows the relationship between minimum die face
temperature and maximum cavity fill time for various wall
thicknesses.

MINIMUM DIE TEMP. v MAXIMUM FILL TIME

FOR VARIOUS WALL THICKNESSES

STICKING NORMAL RANGE SOLDERING

I
80

70

60

50

40

30

20

10

0 I I I I I I I I
240 280 320 360 400 440 480 620 660
DIE FACE TEMP DEG F.
 EASTERN ALLOYS, INC.

STEP 3:

EXTERNAL DEFECTS -- DIAGNOSIS AND CURE:

Diagnosis requires care and skill. An incorrect diagnosis is worse

than none at all, since you may easily make matters worse.

Defects do not normally appear separately, but several are present

together, often in the same area of the casting.

You will need:

•
Bright lights - good fluorescent lights plus an adjustable
spot lamp.
•
A magnifying lens or binocular microscope.
•
Polishing buff or steel wool.
•
Photo copier or camera.
•
Sharp knife.
Make a Careful Examination:

Examine all the evidence carefully step-by-step, take your time and
be thorough.

Obtain details of all the process variables in Step #2. Carry

out calculations and predictions as necessary.

Carefully examine several castings using every technique

available - eg., hand lens or microscope before and after
polishing. Cut open blisters with a craft knife. Use photocopy
machine to record flat surface details.

Record relationship of defect position to gates, overflows, fill

pattern, etc.

Above all take time. A diagnosis made in less than 30 minutes

is likely to be incorrect.

The following table is a useful guide, but exceptions are common.

 DIAGNOSING SURFACE DEFECTS

Appearance Position Causes Cures

Cold Shut All Over • Fill time • Improve fill
too long conditions
• Die temperature • Increase die
too low temperature

Splash & Spatter • Fill time and • Improve fill

die temperture time and/or
marginal die temperature
at end of
• Poor control • Improve feed
over first design and
metal in fill pattern

at "windows" • Excessive swirl • Improve fill

vortex still time and/or
present at time die temperature
of solidification
• Improve fill
• Fill time and pattern
die temperature
• Flash over
marginal
cut-outs

k /
Lamination • Dies separating • Check die lock
during filling
• Check tool
support

Blisters • Trapped air • Increase gate

or die lube velocity
• Gases not • Reduce
well distributed lubrication
• Improve venting
• Increase freeze
time
 DIAGNOSING SURFACE DEFECTS

Appearance Position Causes Cures

Sink Marks • Liquid/solid • Improve design
Sink mark
contraction to eliminate
• Lack of feed • Achieve optimum
to local thick fill conditions
sections

Lakes • • Optimize tool

temperature

extraction rate
of tool halves

• Shrinkage due • Treat as shown

to local hot in appropriate

• Fine cold shuts

• Gas porosity

• Zinc dissolves • Remove cause

iron of die
• Take off at
least 0.002"
• High temperature from surface
• Oxide bloom • Oxidize die
removed from
die surface

Drag Marks • Under cuts • Increase draft

• Reduce "freeze"
shrinking on to
• Eliminate
• Oxide coat lost
and soldering
 EASTERN ALLOYS, INC.

STEP 4:

INTERNAL DEFECTS (POROSITY) DIAGNOSIS AND CURE:

There are many types of internal defects, some more dangerous or

unacceptable than others, depending on the application.

The position and type of defect is often more important than the
quantity. Quantitative assessment is difficult and usually
subjective.

As with surface defects, it is usual to find several defects in

association, for instance gas trapped in the inflowing molten metal
will usually migrate to the areas where shrinkage contraction
occurs as the metal solidifies. Removing the gas will change the
form of the defect (probably from spherical to inter-dendritic),
but probably not affect the position and quantity.

You will need:

• Saw, hammer vise
• File, emery paper (or preferably) polishing equipment
Bright lights - adjustable spot lamp
Magnifying lens or binocular microscope
• Sharp scriber or needle

Optional extras:
• Crack detecting equipment (eg., dye penetrant spray cans)
• X-ray equipment
• Lathe or milling machine to cut consecutive sections

Method:
• Make surface examination first - use crack detection where
appropriate. Look for external evidence which indicates
internal defects. eg., Sink marks may indicate internal
shrinkage porosity.
• Examine process data for indications of defects likely to be
present, Calculate fill time, gate velocity, etc.
• Examine internal structure by any appropriate means:
X-ray will show most of the internal structure, but
needs a skilled technician to interpret the results.

Sawn or machined sections will show internal. structure

at the section chosen. Be careful that defects are not
burred over.

Half-sawn and broken sections are preferred since it

avoids burring.

The following table is a useful guide, but exceptions are common.

 DIAGNOSING INTERNAL DEFECTS

Appearance Position Causes Cures

Spherical shiny Uniformly dispersed Gased metal . Degas metal
(Hydrogen) . Increase metal
Aluminum only pressure

Spherical dull Corners . Lubricant . Reduce plunger

. Air and die lube
. Water vapor (Zn .06 oz/lb)
Gate . Use correct (Al .1 oz/lb)
. gate velocity diluted lube
. Reduce runner
volume
. Look for cracked
tool
. Use correct gate
velocity

Swirls Close to surface . Cold shuts . Reduce f ill time

folded in . Increase die and
. Trapped air, metal
etc. temperature
. Improve
circulation
within the die

Irregular rough Centers of section . Shrinkage . Use lower metal

porosity temperatures
. Thick . Design “out”
sect ions thick sections
. Hot spots . Use high final
. High pressure
temperatures

Intergranular Center line and thick . Shrinkage . “Design out”

sections
. Low metal and

Cracks Sharp corners Shrinkage plus . Reduce die close

noncontinuous) stress time
. Eliminate hang
ups
. Blend corners
. Add buttresses