How to solve Casting faults

Casting failures

Part not compl. full 2

Flash 3

Micro pores 4

Pores 4

Blisters 4

Shrinkage 4

Stretcher strains 5

Metallizing 5

Dimensional faults 6

© Copyright Bühler Druckguss AG 15.06.01, CH 9240 Uzwil GUSSFEHLER_6.P65 Seite 1

How to solve Casting faults
Casting not completley full

possible causes

The die filling time is too

long.The Alloy is not liquid
anymore at the end of the die
filling.

Braking / Switch over v>p Die temperature too low

not setted ok.

Velocity of filling phase is too Metall temperature to low

slow. Die filling time depends
on wall thickness of casting
Imprtant: Watch Gate velocity
vMA! (Al 30 -60 m/s)
Alloy viscosity too high,the flow
characteristics of the alloy have
Metall flow design not good. changed or are not ok.
M;aybe prefilling of casting
needed or start the filling
phase already in the runner.

Slow shot takes too much

time. (Filling ratio?)

Checkventing area (vAir

max.: 300 m/s)

Check the casting quality and

release

Production

© Copyright Bühler Druckguss AG 15.06.01, CH 9240 Uzwil GUSSFEHLER_6.P65 Seite 2

How to solve Casting faults

Flash

possible causes

Die parting line not tight

or Metalpressure too high

Check filling speed

Touch die parting surface with

touching ink and small locking Check there is a high dynamic
force. pressure peak at beginning of
intensification phase

Increase the locking force Braking adjustment

step by step and watch .

Check switch over point

(filling to pressure phase)

Check metall pressure while

intensification phase. (The
opening force should be less
than the locking force of the
machine)

reduce intensification pressure

delay intensifier

Check the casting quality and

release

Production

© Copyright Bühler Druckguss AG 15.06.01, CH 9240 Uzwil GUSSFEHLER_6.P65 Seite 3

How to solve Casting faults

Micro pores Pores Blisters Shrinkage

Hydrogen have been Not enugh metall has
released during the possible causes been feeded to the
solidification. cavityduring
Gases have been mixed with the Metall solidification of the
during the filling process. casting.

Are the pores/

blisters discolored?
Check intensification
Check the Alloy Yes No phase setting
Relationship
between new alloy
increase
and remelted
intensification
material.
pressure:
Disolored pores/ Check die venting at For standart parts
blisters are related to cavity, and die frame. min400 bar
Decontamine alloy plunger lub, Heating Check the calculated For parts with mech.
for example with oil or spraying agent velocity of the air requirements
nitrogen vAir* max 300m/s 400 – 600 bar
For pressure tight
parts
Inclusion of hydrogen
Check slow phase 800 – 1000 bar
during melting Check plunger
process with and fast
lubrification reduce decrease metall
phasefilling test.
quantity of lub temperature

If nothing seems to Decrease cavity

Check tightness of
eliminate the problem: temperature at
heating lines.
increase critical areas
intensification
pressure to reduce the correct spraying
size of the pores process
Correct spraying
process
Check die cooling
system

Check casting alloy

Check the casting quality and
release

Production

© Copyright Bühler Druckguss AG 15.06.01, CH 9240 Uzwil GUSSFEHLER_6.P65 Seite 4

How to solve Casting faults

Scratches Metallizing

possible causes

While die opening or Aluminium is building

ejecting mecanical up on the die steel
friction at casting
surface

Check the spraying

process
Check the angels of
the cavity Check the concentration
of the spraying agent
Check the spraying
process Check the die temperature
at thecritical area. Maybe is
to high. (max 220 °C after
spraying
Check the cavity surface

Check the cooling

circuits
Check the trimming tool
Metall speed at gate is
too high. (Al 30- 60 m/s)

Metall pressure is too

high.

Check the temperature

and quality of the alloy.

Check the casting quality and

release

Production

© Copyright Bühler Druckguss AG 15.06.01, CH 9240 Uzwil GUSSFEHLER_6.P65 Seite 5

 How to solve Casting faults

Dimensional problems

possible causes

Deformation while Deformationwhile Deformation while Deformationwhile

casting solidification/ cooling trimming
ejection

The part is too hot

when the die opens
Core is in incorrect Try to cool the part by Check trimming tool
Check biscuit Air
position
ejection andstroke“
die open damped“
Cavity is not Check the wayyou
in the right position. enter the casting Check casting
Maybe ejector rods into the cooling temperature while
not at the right tank trimming
position

Ejector movement is
too fast.

Check spraying
process. (Part
sticking on cavity)

Ejectorplate is not
parallel

Check casting quality and

relase

Production

© Copyright Bühler Druckguss AG 15.06.01, CH 9240 Uzwil GUSSFEHLER_6.P65 Seite 6