DIE-CASTING

GUIDEBOOK
Types and Troubleshooting of Die-casting

DIGITAL MICROSCOPE IMAGING EXAMPLES

 What is Die-casting?

Die-casting is a casting method that pours molten metal into shape under high pressure using moulds.
Generally, die-casting refers to those specifically performed under high pressure. Cast products themselves are
also called die-castings.
The most commonly used molten metals for die-casting are aluminium alloy, zinc alloy, and magnesium alloy.

Typical Casting Methods

Die-casting Sand mould casting Gravity casting Low pressure casting

This is a casting method that pours
molten metal into a pair of moulds
under high pressure. This method
features the highest productivity
and dimensional accuracy among
all casting methods. It also allows
easy secondary processing thanks
to a smooth casting surface.
This is the oldest casting method,
which pours molten metal into a
mould made of sand.
Compared to a metal mould, this
method has a lower dimensional
accuracy and a rougher casting
surface, but is suitable for high-mix
low-volume production.
This is a casting method that pours
molten metal into a mould by
gravity.
This is a casting method that pours
molten metal into a mould under low
pressure. This method applies air
pressure to the molten metal
surface to pour metal into the
mould.

Differences by Material

Material Feature

Most widely used due to a light weight, low cost, and high recycle efficiency.
Aluminium alloy die-casting Compared to zinc alloy die-casting, it features higher electrical/thermal conductivity, corrosion resistance, and workability
as well as a lighter weight and a higher strength.

Used for cases of precision devices because of its extremely high dimensional accuracy and high shock absorption as well
as its ability to provide a thin moulding.
Zinc alloy die-casting
This is also used in applications for automobiles and cases for watches because it allows easy plating and painting.
This die-casting also features a longer mould duration than aluminium die-casting.

Used for lightweight applications such as notebook computers and mobile phones because it offers a lighter weight and
Magnesium alloy die-casting
a higher electrical/thermal conductivity than aluminium while having a higher strength than plastic.

Features of Die-casting

Feature Description

Molten metal is poured into a pair of moulds under high pressure to allow high-volume production in a short time.
High productivity
Several tens of thousands of products can be produced using a single pair of moulds.

A high dimensional accuracy facilitates secondary processing such as cutting. A smooth casting surface also allows easy
High dimensional accuracy
plating and painting.

Thin moulding Can offer the thinnest moulding among all casting methods and produce products with a higher strength than plastic.

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 What is Die-casting? Manufacturing Cycle and Defects Imaging examples

Structure of Die-cast Machine

A die-cast machine consists of a mould clamping component that is composed of a movable mould and a fixed mould, an
injection component that injects molten metal into the pair of moulds, and an extrusion component that discharges cast
products from the moulds. Machines with the injection component outside molten metal are called cold chamber type and
those with the component inside molten metal are called hot chamber type. The size of a die-cast machine is expressed by its
mould clamping force (in tons).

Cold chamber die-cast machine

Vent hole Overflow (basin)
Due to high casting pressure, large die-castings Fixed mould
Eject pin
can be produced with this method. However, this Molten metal
(extrusion pin)
method requires a longer cycle time than the hot Filling port
chamber die-cast type because molten metal Cavity Ladle
needs to be poured. The structure also makes it
easier for air and oxides to enter. To prevent blow Gate
Movable
holes, special die-casting methods may be used Liner (runner)
mould

such as vacuum die-casting and nonporous Sleeve Cylinder

die-casting. Plunger

Hot chamber die-cast machine Fixed mould

Mould
Used for zinc and magnesium alloy casting.
This machine has a low casting pressure but Nozzle
enables a shorter cycle time because the molten
metal does not need to be poured. This method Movable Plunger
also reduces the entry of unwanted air and mould

oxides.
Pot

Molten
metal

Structure of Mould Assembly

In a mould assembly, the convexed part is called main core and Movable mould Fixed mould
the concaved part is called cavity. Generally, inserts are mounted
in master moulds to facilitate replacement.
Core
The cavity is positioned on the fixed side and the main core on the Main core
movable side. A core is used to make a hollow or a hole in a Cavity
product. After casting, the core is removed from the insert when
the product is ejected.
Please note that a hollow in a mould is also called a cavity. Inserts

Master moulds

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 Manufacturing Cycle and Defects

Manufacturing Cycle of Die-cast Machines

After moulds are mounted, a die-cast machine repeats the following five steps to achieve highly productive manufacturing:

1 Apply mould release agent 2 Clamp moulds 3 Fill molten metal

Sprays mould release agent. Closes the movable mould to apply Fills molten metal from the filling
clamping pressure. port using a ladle.
Movable mould Fixed mould

4 Inject and pressurise 5 Eject

Injects molten metal into the cavity After cooling for several seconds,
using a plunger and pressurise it. opens the movable mould and
discharges it using an eject pin.

Die-cast-related Terminology

Term Description Term Description

Vacuum die-casting A casting method that depressurises the cavity to enable heat
Master mould A metal block (movable or fixed) that accommodates an insert
method treatment and welding with less cast holes (blow holes)

A casting method that enables heat treatment and welding while

Nonporous die-casting preventing cast holes by feeding oxygen (active gas) before
Insert A metal block to be mounted on a master mould to make a cavity
method injecting molten metal to reduce the pressure through an
oxidation reaction with the molten metal

A cylindrical container for molten metal, To be removed from an insert when die-casting is ejected to form
Sleeve Movable core
in which a plunger moves an undercut

A device that injects molten metal in a sleeve into a pair of To be mounted in a pair of moulds and ejected with the
Plunger Core
moulds die-casting to create a hollow

Ladle A bucket-like container that supplies molten metal to a sleeve Casting surface The surface of a die-casting

Eject pin An angle provided for die-casting to be ejected easily from a core
Used to eject die-casting from a pair of moulds Draft angle
(extrusion pin) or the side of a mould

Parting line The joining surface of a master mould or movable core, which An extended part of a mould by taking shrink of die-casting into
Shrinkage allowance
(mould parting surface) also appears as a line on die-casting account

Hot metal Same as molten metal Finishing allowance Part to be removed during finishing of die-casting

Liner (runner) A passage of molten metal from sleeve to cavity Boss A protrusion provided on die-casting

Gate An inlet for molten metal between the liner and cavity Rib A reinforcing bar provided on die-casting

Overflow A cavity provided separately from the one for products to remove A part of die-casting that cannot be removed even when the
Undercut
(basin) leading, dirty molten metal or facilitate molten metal flow paired moulds are opened

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 What is Die-casting? Manufacturing Cycle and Defects Imaging examples

Typical Casting Defects

Terms Causes Countermeasures

A blow hole generated by entry of air or gas in molten metal, or a shrinkage cavity
Cast hole
generated due to a short supply of molten metal
Adjust the casting pressure, change the vent hole, adjust the amount
of mould release agent to be applied, or change the position and size
of the gate

Shrinkage Depression following a slow cooling due to a partially overheated mould Adjust the mould temperature or redesign the mould

Insufficient filling
The area near the gate cools down too quickly to fill the entire cavity with molten Change the mould temperature, adjust the molten metal temperature,
(poor run of molten
metal or change the position and size of the gate
metal)

A low mould temperature and a low pouring pressure cause molten metal to be
Cold shut Raise the mould temperature, the molten metal temperature, and the
solidified before spreading entirely in a pair of moulds, generating a mark at the
(weld mark) plunger speed, or change the position and size of the gate
joining point

Crack/distortion An insufficient draft angle, an uneven shrink, or an improper extrusion Redesign the shape or change the extrusion position

A solidification layer generated in the sleeve enters the cavity and then be contained
Broken chill layer Adjust the molten metal temperature and the plunger speed
in die-casting

Raise the mould temperature and reduce the amount of mould release
Flow mark A low mould temperature or too much mould release agent
agent

Sufficiently polish the mould surface and provide an appropriate draft

Scuffing Die-casting adhered to a mould when being ejected or an improper draft angle
angle

Change the type or application method of mould release agent or

Seizure A partially overheated mould causes adhesion with the molten metal
redesign the mould

Blister Compressed gas near the surface is expanded to cause swelling on the surface Prevent blow holes and extend the mould cooling time

Discoloration The die-cast surface discolored by one or more mould release agent components Change the agent

Rough surface A rough mould surface is reflected directly on the die-cast surface Clean and polish the mould

A hard foreign substance enters in molten metal to cause, for example, breakage of
Hard spot Filter molten metal
a grinding tool

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 Imaging examples

HDR function Examples of Images Captured by Digital Microscope

High

Can capture a target with metallic lustre without glare.

OK
Low

VH-Z00, 10: Normal image HDR image

Wide magnification range Examples of Images Captured by Digital Microscope

A single lens enables you to capture images from low to high magnifications (from 0.1 min. to 5,000 max.).

VH-Z00, 5 10

20 50

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What is Die-casting? Manufacturing Cycle and Defects Imaging examples

3D imaging Examples of Images Captured by Digital Microscope

The 3D capture function allows 3D capture of die-

casting. Profile measurement is also possible using an
optional 3D measurement software.

Cast hole (blow hole): VH-Z20, 200 Measurement sample of profile

Mould crack: VH-Z20, 200 Measurement sample of profile

Comprehensive light shift function Examples of Images Captured by Digital Microscope

The light shift function offers a wide selection of lights

including bright-field, dark-field, DIC, polarisation,
combination illumination, and transmitted illumination.

Bright-field (coaxial illumination): VH-Z100, 500 (flow of molten metal)

Quantification Examples of Images Captured by Digital Microscope

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The automatic measurement function enables quantification simply by capturing an image.

Casting surface: VH-Z20, 200 Automatic measurement sample of area

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