Diecast Defects Manual

transcript

PRESSURE DIE CASTING DEFECTS MANUAL

Sheet no : PDCM 1

Sheet no : PDCM 2

CLASSIFICATION OF DEFECTS

Surface defects or visual defects :

Cold shutCrackDragDamageChip offGate blow holeShrinkage. Heat sink markPeel offBlistersSoldering

Internal defects/ After machining defects

Blow holeInclusion

Pin hole porosityNon clearance.

Sheet no : PDCM 3

Cold shut

Intensifier not put on.Cycle time more.Less air spray.

Die Process

Water leakOverflow blocked.Vent blockedFlash from the die

MachineLower metal temperature.More die coat spray

Less die temperature.Dragging plunger tipLow / high first phase velocityLess/more velocity based on locationFlash from plunger tip..Fast shot start position.

Less jumping pressure.Less Accumulator pressure.Less / more biscuit thickness.N2 pressure ~ Acc pressure Shot not effective.

Material

Low Si content.Un drossed metalMore diecoat dilution.High Fe content.

Sheet no : PDCM 4

Cold shut

DieWater leakOverflow blocked.Vent blockedFlash from the die

Crack in insert at water line area

Water line cut at ejector pin area

Coating leak from Auto sprayer

Water leak in injection rod

Sheet no : PDCM 5

Ejector pin broken at overflow area

Over flow gate blocked

Overflow catch up in previous shot

Cold shut

Sheet no : PDCM 6

Flash catch up at vent

Overflow catch up in previous shot

Cold shut

Sheet no : PDCM 7

DieWater leakOverflow blocked.Vent blockedFlash from the die Die matching not proper.

Casting pressure exceeding M/C locking force.Chill vent area not matching.Die bulged.Die Insert is retracted or to the level of housing .Higher metal temperature.Worn out toggle link.Worn out platen shoe.

Cold shut

Sheet no : PDCM 8

More Shot delay time.More Auto ladle waiting time .Auto ladle forward speed slow.Temperature indicator not working.Variation in topped metal temperature.Coil not working.No auto switch - on working.Cold auto ladle.

Cold shut

Process

Lower metal temperature.

Low / high first phase velocity

More die coat spray

Less die temperature.Dragging plunger tip

Less/more velocity based on locationFlash from plunger tip..Fast shot start position.

Loss at shot sleeve

Loss at furnace

Sheet no : PDCM 9

Cold shut

Process

Lower metal temperature.More die coat spray

More spraying time.More Quantity of diecoat spray .Settling of die coat .

Time set morecatch up prone areaLess draft areaLess water cooling area

Leaking spray headMore no of nozzlesApplication of raw die coatto avoid catchup

Coat drain hole blockedSide core areaHorizontal land in die No effective air spray

Sheet no : PDCM 10

Cold shut

Process

More water coolingMore die coat spray.Initial startup.

Waterline opened after stoppage

Sheet no : PDCM 11

Cold shut

Process

Worn out plunger tip.Worn out shot sleeve.Less lubricant in plunger tip.Misalignment between plunger and injection .Mismatch between sprue bush and shot sleeve.

Sheet no : PDCM 12

Cold shut

Process

Set in wrong position

Valve getting loosened while runnimg.

Sheet no : PDCM 13

Cold shut

Process

Set in wrong position

Limit switch problem

Sheet no : PDCM 14

Cold shut

Process

Wornout plunger tip

Wornout shot sleeve

Wornout sprue bush

Sheet no : PDCM 15

Cold shut

Process

Less die temperature.Dragging plunger tipLow / high first phase velocityLess/more velocity based on locationFlash from plunger tip..Fast shot start position. Set wrongly

Poor response from limit switch

Sheet no : PDCM 16

MachineLess jumping pressure.Less Accumulator pressure.Less / more biscuit thickness.N2 pressure ~ Acc pressure = 30 kg/cm 2

Shot not effective.

Low nitrogen pressure

Set value not as per standard

Cold shut

Sheet no : PDCM 17

Shot not effective.

Cold shut

Refer PCM #

Sheet no : PDCM 18

Shot not effective.

Cold shut

Auto ladle angle variationAl spill from auto ladleCold metal strucjk at nozzle of ladleLess or more intensification pressureLoss of Al due to flash from die.

Sheet no : PDCM 19

MachineLess jumping pressure.Less Accumulator pressure.Less / more biscuit thickness.N2 pressure ~ Acc pressure Shot not effective.

Cold shut

30 Kg/cm2 ( For eg : If Acc pr = 140 N2 pressure should be 110 Kg/cm2)

Sheet no : PDCM 20

MachineLess jumping pressure.Less Accumulator pressure.Less / more biscuit thickness.N2 pressure ~ Acc pressure

Cold shut

Shot not effective. Oil in N2 cylinder.More intensification delay.Less second phase velocity.

Sheet no : PDCM 21

Die Process

Soldering in dieBend ejector plate

MachineHigher metal temperature.Less die coat spray

More die temperature.Biscuit catch up in plunger tipMore gate velocity Less/More dwell time

More jumping pressure.Improper machine platenalignment.Improper side core sliding.Die opening speed more. .

ManMaterial

Less diecoat dilution.Low Fe content.

Improper coating

Sheet no : PDCM 22

DieSoldering in dieBend ejector plate

Fe content < 0.8 %No effective water coolingNear to gate .Less die coat spray.

Sheet no : PDCM 23

Process

Higher metal temperature.Less die coat spray

More die temperature.Biscuit catch up in plunger tipMore velocity based on location.Less/More dwell time

Temperature indicator not working.Variation in topped metal temperature.No auto switch - on working.

Sheet no : PDCM 24

Process

Higher metal temperature.Less die coat sprayMore die temperature.Biscuit catch up in plunger tipMore velocity based on location.Less/More dwell time

Less spray timeNo spray head nozzle focused to defectprone area. Inaccessible area to spray head.

Sheet no : PDCM 25

Process

More die temperature.Biscuit catch up in plunger tipMore velocity based on location.Less/More dwell time

Near to gate area.No effective water coolingMore wall thickness area.

Sheet no : PDCM 26

Process

No water cooling to plunger tip and sprue bushFlash in plunger tip.No forward stroke of plungerto push the biscuit.Length of the plunger tip less.Dragging in sprue bush.

Sheet no : PDCM 27

Process

More second phase velocity.

Length of first phase velocity is below the gate.

Sheet no : PDCM 28

Process

More die temperature.Biscuit catch up in plunger tipMore gate velocity Less/More dwell time More T2 timing setting.

More ejection time after die opening.

Sheet no : PDCM 29

MachineMore jumping pressure.

Improper machine platen alignment.

Improper side core sliding.

Die opening speed more.

Worn out Toggle linksWorn out platen shoes.Fixed die platen flexure.

Set value more

Worn out side core guide waysWorn out core pull rod

Valve setting more.

Sheet no : PDCM 30

Die Process

Soldering in dieRough surface after die polishingUnder cut in dieHeavy heat check marks

MachineHigher metal temperature.Less die coat spray

More die temperature.More gate velocity Less/More dwell time

More jumping pressure.Improper machine platenalignment.Die opening speed more. .

ManMaterial

Less diecoat dilution.Low Fe content.

Improper coating

Sheet no : PDCM 31

Process

Temperature indicator not working.Variation in topped metal temperature.No auto switch - on working.

Sheet no : PDCM 32

Less spray timeNo spray head nozzle focused to defectprone area. Inaccessible area to spray head.

Process

Higher metal temperature.Less die coat sprayMore die temperature.More gate velocity Less/More dwell time

Sheet no : PDCM 33

Process

Near to gate area.No effective water coolingMore wall thickness area.

Sheet no : PDCM 34

Process

More second phase velocity.

Length of first phase velocity is below the gate.

Sheet no : PDCM 35

Process

More die temperature.More gate velocity Less/More dwell time More T2 timing setting.

More ejection time after die opening.

Sheet no : PDCM 36

Chip off

Die Process

Catch up in dieMatl projection in gate.

MachinePrefilling in Casting.

Low metal temperature.Ineffective shot

Cold metal from auto ladleMore breaking force

Biscuit catchup in sprue bush.Improper trimming. .

ManMaterial

Diecoat matl at gate. Improper handling of castings.

Sheet no : PDCM 37

DieCatch up in dieMatl projection in gate.

Chip off

Less die coat spray

Die chipped off

Sheet no : PDCM 38

Process

Prefilling in Casting.

Cold metal from auto ladleMore breaking forceNo support in casting

Chip off

First phase velocity ends beyond the gateLow die temperature.

Sheet no : PDCM 39

Process

Chip off

More shot delay timeMore autoladle waiting timenear shot sleeveOxide layer from furnace

Sheet no : PDCM 40

Process

Chip off

More weight hammer.Position of holding casting while breaking.

Sheet no : PDCM 41

ProcessPrefilling in Casting.

Chip off

More Shot delay time.More Auto ladle waiting time .Auto ladle forward speed slow.Temperature indicator not working.Variation in topped metal temperature.Coil not working.No auto switch - on working.Cold auto ladle.

Loss at shot sleeve

Loss at furnace

Sheet no : PDCM 42

ProcessPrefilling in Casting.

Chip off

Oil in N2 cylinder.More intensification delay.Less second phase velocity.

Sheet no : PDCM 43

Chip off

MachineBiscuit catchup in sprue bush.Improper trimming.

No water cooling to plunger tip and sprue bushFlash in plunger tip.No forward stroke of plungerto push the biscuit.Length of the plunger tip less.Dragging in sprue bush.

Sheet no : PDCM 44

Chip off

MachineBiscuit catchup in sprue bush.Improper trimming No proper location for

Casting in trimming die.Improper alignment of trimming die.Bend trimming plate.Bulging in edge of the trimming pin.

Sheet no : PDCM 45

Material

Diecoat matl at gate.

Chip off

Less draftMore drag mark area.Prone to casting catch up.

Sheet no : PDCM 46

Peel off

Die Process

Flash from the dieLess die temperatureDie surface roughness

Machine

Oxide layer from metalShot blasting current .Shot blasting time.Flow marks .

Fast shot starts from gate.Improper gate velocity.

Intensifer action improperMore second phase velocityMore intensification delay.

ManMaterial

Less Cu content More die coat spray

Sheet no : PDCM 47

Peel off

DieFlash from the dieLess die temperatureDie surface roughness

Die matching not proper.Casting pressure exceeding M/C locking force.Chill vent area not matching.Die bulged.Die Insert is retracted or to the level of housing .Higher metal temperature.Worn out toggle link.Worn out platen shoe.

Sheet no : PDCM 48

Peel off

DieFlash from the dieLess die temperatureDie surface roughness

More water coolingMore die coat spray.Initial startup.

Waterline opened after stoppage

Sheet no : PDCM 49

Peel off

DieFlash from the dieLess die temperatureDie surface roughness Soldering in die

Die not serviced after taking corresponding shots.

Sheet no : PDCM 50

Peel off

Process

Improper gate velocity.Fast shot starts from gate. S1 set value more

More first phase velocity.

Sheet no : PDCM 51

Peel off

Process

Oxide layer from metalShot blasting currentShot blasting time.Flow marks .

Improper gate velocity.Fast shot starts from gate.

Second phase velocityMore intensification pressureBlock in gate due to cold metal.

Sheet no : PDCM 52

Peel off

Process

Metal not cleaned properly

Sheet no : PDCM 53

Peel off

Process

Less shots load to impellerFilter block.

Sheet no : PDCM 54

Peel off

Process

Oxide layer from metalShot blasting current .Shot blasting time.

Set timing moreRe shot blasting

Flow marks .

Sheet no : PDCM 55

Peel off

Process

Oxide layer from metalShot blasting current .Shot blasting time.

Flow marks . Initial startup water line open

Sheet no : PDCM 56

MachineIntensifer action improperMore second phase velocityMore intensification delay.

Peel off

Less N2 pressure

Sheet no : PDCM 57

MachineIntensifer action improperMore second phase velocityMore intensification delay.

Peel off

Set value more

Diecast Defects Manual

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