Detecting anomaly of die casting

This case study is excerpted from the IVI (Industrial Value Chain Initiative), Business Scenario WG activities.

Issue

Casting nests occasionally occur in aluminum die casting production

• Casting cavities occur due to differences in casting machines, even though they are produced under the same conditions.
• We don't have the true cause of what is causing the casting nests.

Solution

A piezoelectric load sensor, PiezoBolt, was installed to detect the pressure applied to the extrusion pin and measurements was taken.

As a result, it was found that differences in molten metal temperature and die temperature caused discrepancies in the timing of pressure buildup. The timing discrepancy also changed the way molten metal flowed, and the cause of casting cavities was identified as the inability to release internal gases.

Result

Optimization of casting conditions to reduce defect rate

• We were able to elucidate the mechanism of casting nest generation.
• Casting conditions were optimized and the defect rate was reduced.