Quality Procedure

DIE CASTING
(Control of Production and Service Provision)

Clause 8.5.1
ISO 9001: 2015

Activity Name Designation Signature

Prepared by Deedar Hussain Magsi D (DC)

Head
Reviewed by Lt. Col(retd)Nasir Mehmood
(MT/DC)
Head
Lt. Col(retd)Nasir Mehmood
(MT/DC)
Approved by
Riaz Moazzam COO
Revision No.: 01
Doc. No. QP/DC/8.5.1-B
Date: 04/04/2024
Pakistan Machine Tool Factory, Karachi

Quality Procedure Document #

Die Casting QP/DC/8.5.1-B
1. Purpose: -
The procedure ensures production of Die Cast Items within the required specifications
under the documented system.

2. Scope: -
This procedure concentrates mainly on Pressure Die Casting Process in the Die Casting
Department. Machining of the components in this department is covered under the quality
procedure Process Control Doc. No: QP/PPC/8.5.1.

3. Responsibility: -
3.1 Head of Production is responsible for compliance with the procedure to ensure that the
production is carried out as per details mentioned in the procedure and documents
mentioned therein.
3.2 Incharge Die Casting is responsible for maintaining & counter checking the process
parameters and meeting the quality requirements mentioned in the procedure and related
documents.
3.3 Incharge Quality Control is responsible for ensuring that the production is being carried out
under controlled process parameters as per Machine Setting Sheet (Annexure-9.1) & QC
Checklist (Annexure-9.3) meeting all the quality requirements.
3.4 Head Maintenance Department is responsible for maintaining the machine & equipment in
such an acceptable condition that the process parameters referred in this procedure,
especially those mentioned in the Machine Setting Sheet (Annexure-9.1) are controlled &
demonstrable within required limits.

4. Authority: -
Head of Manufacturing Division is authorized for the approval and any amendment in this
procedure.

5. Execution: -
5.1 General: -
The execution procedure has been divided into three steps in the following sequence:

INPUT PROCESS OUT PUT

Each of these has been divided & subdivided in the following sub clauses.

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Quality Procedure Document #

Die Casting QP/DC/8.5.1-B

5.2 INPUTS: -
5.2.1 Man Power: -
 The manpower directly involved in production is employed on the basis of qualification,
training and experience. Minimum qualification for Die Casting Machine Operator is 8 th
class pass with training on DC machines at PMTF or outside experienced in this trade.
However, qualification requirement is relaxed in favor of skill, experienced & quality
consciousness.

5.2.2 Material: -
a) Mostly two types of Aluminum alloys, PMTF standard AS12U1 & AC-9 are used. Inspected
& okayed material ingots as per casting drawing (available in the department) are supplied
by production Control Department which are separately stacked in the designated store
area. The gates, runners, cover flows & rejected components are also re-melted with these
ingots with a ratio which does not exceed one part of scrap to two parts of the virgin
material.
b) INSERTS as per Inserts (available in the Department) duly inspected & okayed are
delivered by production Control Department which are separately stored in the containers
with identification tags.
c) lubricants for plungers etc. presently being used is:
 TYBE TRENNEX (854G), Graphace-3700 & Tie Lubricant Flux B-200R.
d) Die Spray presently being used is:
 TRENNEX 550 WL (BARREL).
e) Coverall (flux) is used to protect molten metal from oxidation by making a buffer between
it and the atmosphere. The slag formed should be removed from surface lest it is poured
with the molten resulting in defective casting.
f) CURCIBLE for Melting and Holding furnaces are procured in Silicon Carbide material as
per PMTF stock Nos. 8192 125 & 192 130.
g) Undercoat & primers plunger Tip (70mm) Fuse Coating.

5.2.3 Machine & Dies: -

a) The machine suitable for a job is selected by using equation relating projected Area of the
job, Injection Pressure, Locking Pressure/Force etc. The machine so selected is mentioned in
the Machine Setting Sheet (Annexure 9.1). The machine is kept in order in respect of
injection Pressure, Locking Pressure, Setting of stroke length & timings for the three phases
of injection temperature control, cooling system, and geometrical accuracy requirements.
b) Dies are mostly manufactured in PMTF as designed by Tool Design Department keeping
in view the manufacturing, operation/use and quality requirements of the component. The
dies are numbered for identification as per die drawing which specifies the component to
which it belongs. The dies and accessories e.g. Plunger, Sleeves etc. inspected & found
okayed in Tool Room are handed over to Die Casting Department for production use.

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Quality Procedure Document #

Die Casting QP/DC/8.5.1-B

5.2.4 Methods/Documents: -
a) Finish part drawing is the basic document for component manufacturing. Rough part
drawing of casting is made on the basis of these finish drawings. If the component is
 delivered without machining the casting drawing is the final document for product
acceptance. When machining is carried out, it is done according to manufacture
layout/Operation Instructions as specified in Quality Procedure Doc. QP/PPC/7-2.
b) Setting Sheet for Die Casting machines as per Annexure 9.1 is the main document for
setting the process parameters. This is prepared for every single component and contains all
the information related to component. Die, material, machine, furnace, machining settings,
die spray, lubricants etc.
c) Quality Control Checklist (Annexure 9.3) is the document pertaining to continuous
monitoring of the process parameters & important quality characters of the output. This
contains checks for metal temperature, surface finish, destructive porosity, cracks, damages,
inserts location, flash and biscuits etc. also the critical dimension are checked & recorded in
a separate Critical Dimensions list maintained for each type of component.
5.3 Die Casting Process: -
5.3.1 General: -
Pressure Die Casting is a processed in which molten metal (mostly Aluminum Alloys in
case of PMTF) is injected into a precisely dimensioned steel mould, within which pressure
is maintained until solidification has been completed. This pressure is applied hydraulically
by the moving portion of the machine against the stationary portion and is called the
locking pressure/force. This locking force, in tons, is the measure of the machine capacity,
and is used to select the machine required for a particular component. Other important
features of the process are the injection pressure & speeds, temperature of the molten
material, timings (specially the dwell time during which die remains closed under pressure)
cooling of the dies etc. ejection of the components use of die spray & lubricants.
5.3.2 Important Quality Characteristics: -
A good die cast component should be free from porosity, cracks, blisters, non-filling of the
component contours, and cold i.e. when the two metal streams fail to join/meet. Good
surface finish is also a requirement, especially for decorative components or those used
without painting etc. Although all these defects are important to be controlled, the porosity
comes out to be the single most important feature to be kept under control in case of Die
Cast components. The dimensional & other requirements mentioned in individual
component drawing are met apart from these general parameters.
Following are the general quality requirements:
1) For Auto Transmission Honda & Suzuki components, the strength is the main
parameter controlling the quality along with good surface finish. Strength is achieved by
minimizing the porosity.
2) For Gas Meter components porosity and cracks are the main quality parameters to be
checked. The porosity is controlled to a minimum and impregnation (Moguliding) is
carried out to ensure leakage free components (reference Surface Treatment procedure.

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Quality Procedure Document #

Die Casting QP/DC/8.5.1-B
QP/ST/8.5.1-D. Leakage testing is carried out for these components which is described in
sub clause 5.4 (h).
5.3.3 Important Process Parameters: -
Following are important process parameters for obtaining good results in Die Casting:
a) Material of crucible used for melting & holding does not interact with the molten metal
 resulting in change of composition.
b) The material to be cast should have enough fluidity to fill the narrowest die impressions
before solidification sets in.
c) Thermocouple & Temperature controlled/regulators are kept in order to ensure metal
temperature to be in required range all the time: 660 °C to 680 °C in case of Aluminum
Alloys used at PMTF.
d) Die is preheated with the help of burners to a temperature separately mentioned for
different die parts in the setting Sheet (Annexure 9.1).
e) The locking force of the machine is sufficiently in excess of the separately force resulting
from the Injection Pressure acting on the projected area of the whole cavity/shot. Same
is the case with all sliding cores.
f) The time interval between pouring the material & completion of injection is kept to a
minimum to ensure complete die filling before solidification starts.
g) Right quantity of metal poured with suitable ladle carrying metal equal to the shot
weight.
h) The stroke length of plunger movement in the first phase should be set so that it forms
the molten metal into a complete cylinder. Inadequate length will not remove the air
which will find way into the mould in the second high-speed phase. Executive stroke
length will cause premature injection (and solidification) of material into mould
resulting in imperfect casting.
i) Speed in the first phase is also a compromise as the excessive speed does not allow air to
escape and the slow movement results in solidification of metal.
j) The second phase is most critical in the injection process. High flow rate is required to
allow filling of the cavity in minimum possible time. This is achieved by a Nitrogen
Cylinder-Accumulator combination which comes into action automatically after end of
the first phase. Excessive speed in this phase does not allow air to escape from vent
holes which causes porosity or non-filling of the cavity.
k) Third phase compensates for volume reduction due to shirking in solidification which
may result in some cases. This phase is not necessarily required in all components.
l) Enough vent holes are present in the die cavity suitable located for quick air escape.
m) Adequate cooling of Impression Blocks & Cores is carried out to avoid overheating of
dies (resulting in heat checks/cracks in the die) and quick solidification of component
necessary for bright surface finish and time saving in Dwell.
n) Enough dwell time is allowed to ensure that solidification is completed under pressure
to achieve high density and strength. This also results in avoidance of being and
possible breakage mechanical ejection.
o) Suitable sprays are used to avoid sticking of material to the die. Lubricants are used for
plungers etc. as mentioned in 5.2.2. (c&d)
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Quality Procedure Document #

Die Casting QP/DC/8.5.1-B

p) Breaking of overflows, gates etc. is done with care do that the components are not
damaged. Mechanical using die & press is being introduced gradually to phase out
manual gate breaking where required.
5.3.4 Machine Setting Sheet: -
 Process parameters as described in 5.3.3 are determined/calculated by Incharge Die Casting
for each component and tabulated in the Machine Setting Sheet (Annexure 9.1) of the
respective components Machine is set and all the parameters are counter
checked/monitored with the help of process Control Sheet (Annexure 9.2) before start of
operation. The Machine Setting Sheet is always available on the machine during production
of the component.
5.3.5 Quality Control Checklist: -

Quality Control checklist (Annexure 9.3) is used continuous monitoring of the process &
quality parameters with a predetermined frequency.
5.4 Quality of Output: -

a) At the time first use of a new die all dimension and characteristics/parameters are
checked as per Casting Drawing or Inspection Instruction of the component. If found OK in
all respects the component samples are submitted to the customer for inspection, functional
test and approval. Production is carried out after receiving the written approval from the
customer. The approved sample is kept at PMTF for reference of surface finish, porosity etc.
b) For repeated use of the same die, without replacement of any functional part of it, only
those dimensions are checked which are liable to be disturbed by in complete closing of die
dimensions & parameters is prepared in the light of previous experience and customer
complaints. This list is maintained as “Critical Dimension List”. These dimensions are
checked and recorded by Quality Assurance Inspectors in the QC Checklist (Annexure 9.3)
as a part of their continuous process monitoring activity.
c) Porosity is checked by cutting/breaking the component at least once a day, and
comparing it with the standard or the approved sample.
d) 100% visual inspection of the production lot is carried out for the defect mentioned in
5.3.2, Quality Parameters.
e) Dents, damages, unwanted residual edges of runners/gates and other defects, if any, are
removed by fitting/ filing, using emery paper. Surface finish is improved by using emery
paper if the requirements are higher than that achievable by the die/process.
f) Nonconforming products are decided as per procedure of Doc. No: QP/QA/8.7. Rejected
components are melted with the raw material as described in 5.2.2 (a) of this procedure.
Inserts of these melted components are scraped if these had been machined. Unmachined
inserts are reused if the hardness and geometrical parameters specially ovality, are found
acceptable.
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Quality Procedure Document #

Die Casting QP/DC/8.5.1-B

g) Gas meter components are sent for Impregnation/Moguliding for filing of micro-
porosity to avoid gas leakage during use (Ref. Surface Treatment Procedure Doc. No:
QP/ST/8.5.1-D.

h) Pressure testing of Gas Meter components is carried out for leakage with the help of the
Testing Equipment available in the department which allows compressed air to enter into
 the cavity of the component which is clamped against a rubber sealing piece with the help
of mechanical clamps. The air pressure for testing is 20 psi and frequency of check is 50-75 pcs.
Per day. The components failing in the test are rejected straightway and corrective action is
taken accordingly.

6. Quality Records: -
6.1 Quality Checklist Form No: 2718 137.
6.2 Customer Approval/Acceptance Report.
6.3 Inspection Certificate Form No: 2718 106.
6.4 Final Inspection Certificate Form No: 2716 006.

7 Definition: -
7.1 Pressure Die Casting:
A Casting process in which molten is injected into a steel mould within which pressure is
maintained until solidification is complete.

8. Reference: -
8.1 ISO 9001:2015 Standards.
8.2 Quality Procedures Doc. No: QP/PPC/8.5.1, QP/ST/8.5.1-B.
8.3 Casting, Finish part & Insert drawings, O.Is for machined components.
8.4 Critical Dimension List.
8.5 Casting Inspection Check Sheet (Inspection Instruction).
8.6 List of Components Die Cast in PMTF.
8.7 Aluminum Die Casting Trouble-Shooting Guide.

9. Appendix: -
9.1 Machine Setting Sheet.
9.2 Process Control Checklist.
9.3 Quality Control Checklist.
9.4 Aluminum Die Casting Trouble-Shooting Guide.

10. Survey of Changes: -

As per Form attached.

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Document No.
SURVEY OF CHANGE

Signature
Edition Date Changes Page(s)
Prepared by Approved