1. Holes and pores
Cause:
1).The gas in the aluminum liquid is not completely removed.
2).Improper mold design or operation leads to the failure of gas to be discharged smoothly.
Solution:
1）.Improve the smelting and refining process of aluminum liquid to ensure sufficient degassing.
2).Adjust the mold design and optimize the exhaust system.
3).Control the die-casting speed and pressure to avoid too fast or too slow to cause the gas to be unable to be discharged.
2. Shrinkage and deformation
Cause:
1).The volume shrinks during the cooling of aluminum liquid.
2).Improper mold design and uneven cooling.
Solution:
1).Optimize mold design to ensure uniform cooling.
2).Adjust the aluminum liquid pouring temperature and mold temperature to control the cooling speed.
3).Use a suitable cooling system and cooling time.
3. Surface defects (such as cracks, pits)
Cause:
1).Poor aluminum liquid fluidity and uneven filling.
2).Improper mold temperature.
Solution:
1).Increase the pouring temperature of aluminum liquid to improve fluidity.
2).Adjust the mold temperature to ensure that it works within the appropriate temperature range.
3).Regularly maintain and clean the mold to ensure a smooth surface.
4. Oxidation and inclusions
Cause:
1).Aluminum liquid is exposed to the air and produces oxides.
2).Impurities are mixed into the aluminum liquid or are not completely removed.
Solution:
1).Improve the protection measures during the aluminum liquid smelting process and use inert gas protection.
2).Improve the aluminum liquid refining process to ensure that inclusions are fully removed.
3).Clean the furnace and tools regularly to avoid impurities.
5. Hot cracking
Cause:
1).Internal stress is generated during the cooling of aluminum liquid.
2).Improper mold design or operation leads to stress concentration.
Solution:
1).Optimize mold design to avoid stress concentration areas.
2).Adjust the cooling rate to control the stress distribution during the cooling process.
3).Use appropriate cooling media and cooling methods.
6. Incomplete filling
Cause:
1).Poor aluminum liquid fluidity or insufficient pouring speed.
2).The mold temperature is too low or the exhaust is not smooth.
Solution:
1).Increase the pouring temperature and pouring speed of the aluminum liquid.
2).Adjust the mold temperature to ensure that it is within the appropriate operating temperature range.
3).Optimize the mold design and improve the exhaust system.
7. Magnetic impurities
Cause:
1).Magnetic impurities such as iron are mixed in the aluminum liquid.
2).Magnetic substances are contained in the smelting equipment or tools.
Solution:
1).Increase the purity of the aluminum liquid and use high-quality aluminum ingots.
2).Regularly check and clean the smelting equipment and tools to ensure that there are no magnetic impurities.
3).Use a magnetic separator to remove magnetic impurities in the aluminum liquid.
8. Aluminum sticking to the mold
Cause:
1).Improper surface treatment of the mold and rough surface.
2).Improper or uneven use of release agent.
Solution:
1).Improve the mold surface treatment process to ensure a smooth surface.
2).Correctly use and apply release agent to ensure uniform coverage.
3).Regularly maintain the mold, check and repair surface defects.
