PRESSURE DIE CASTING DEFECTS MANUAL

Sheet no : PDCM 1
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 2
CLASSIFICATION OF DEFECTS
Surface defects or
visual defects :
Cold shut
Crack
Drag
Damage
Chip off
Gate blow hole
Shrinkage.
Heat sink mark
Peel off
Blisters
Soldering


Internal defects/ After
machining defects
Blow hole
Inclusion
Pin hole porosity
Non clearance.

PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 3
Cold shut

Intensifier not put on.
Cycle time more.
Less air spray.
Die
Process
Water leak
Overflow blocked.
Vent blocked
Flash from the die
Machine
Lower metal temperature.
More die coat spray
Less die temperature.
Dragging plunger tip
Low / high first phase velocity
Less/more velocity based on
location
Flash from plunger tip..
Fast shot start position.
Less jumping pressure.
Less Accumulator pressure.
Less / more biscuit thickness.
N2 pressure ~ Acc pressure
Shot not effective.
Man
Material
Low Si content.
Un drossed metal
More diecoat dilution.
High Fe content.

PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 4
Cold shut
Die
Water leak
Overflow blocked.
Vent blocked
Flash 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
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 5
Die
Water leak
Overflow blocked.
Vent blocked
Flash from the die
Ejector pin broken at overflow area
Over flow gate blocked
Overflow catch up in previous shot
Cold shut
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 6
Die
Water leak
Overflow blocked.
Vent blocked
Flash from the die
Flash catch up at vent
Overflow catch up in previous shot
Cold shut
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 7
Die
Water leak
Overflow blocked.
Vent blocked
Flash 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
PRESSURE DIE CASTING DEFECTS MANUAL
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
location
Flash from plunger tip..
Fast shot start position.
Loss at
shot sleeve
Loss at
furnace
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 9
Cold shut
Process
Lower metal temperature.
More die coat spray
Less die temperature.
Dragging plunger tip
Low / high first phase velocity
Less/more velocity based on
location
Flash from plunger tip..
Fast shot start position.
More spraying time.
More Quantity of
diecoat spray .
Settling of die coat
.
Time set more
catch up prone area
Less draft area
Less water cooling area
Leaking spray head
More no of nozzles
Application of raw die coat
to avoid catchup
Coat drain hole blocked
Side core area
Horizontal land in die
No effective air spray
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 10
Cold shut
Process
Lower metal temperature.
More die coat spray
Less die temperature.
Dragging plunger tip
Low / high first phase velocity
Less/more velocity based on
location
Flash from plunger tip..
Fast shot start position.
More water cooling
More die coat spray.
Initial startup.
Waterline opened
after stoppage
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 11
Cold shut
Process
Lower metal temperature.
More die coat spray
Less die temperature.
Dragging plunger tip
Low / high first phase velocity
Less/more velocity based on
location
Flash from plunger tip..
Fast shot start position.
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.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 12
Cold shut
Process
Lower metal temperature.
More die coat spray
Less die temperature.
Dragging plunger tip
Low / high first phase velocity
Less/more velocity based on
location
Flash from plunger tip..
Fast shot start position.
Set in wrong position
Valve getting loosened while runnimg.

PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 13
Cold shut
Process
Lower metal temperature.
More die coat spray
Less die temperature.
Dragging plunger tip
Low / high first phase velocity
Less/more velocity based on
location
Flash from plunger tip..
Fast shot start position.
Set in wrong position
Limit switch problem

PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 14
Cold shut
Process
Lower metal temperature.
More die coat spray
Less die temperature.
Dragging plunger tip
Low / high first phase velocity
Less/more velocity based on
location
Flash from plunger tip..
Fast shot start position.
Wornout plunger tip
Wornout shot sleeve

Wornout sprue bush
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 15
Cold shut
Process
Lower metal temperature.
More die coat spray
Less die temperature.
Dragging plunger tip
Low / high first phase velocity
Less/more velocity based on
location
Flash from plunger tip..
Fast shot start position.
Set wrongly
Poor response from limit switch
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 16
Machine
Less 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
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 17
Machine
Less jumping pressure.
Less Accumulator pressure.
Less / more biscuit thickness.
N2 pressure ~ Acc pressure
= 30 kg/cm
2
Shot not effective.
Cold shut
Refer PCM #
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 18
Machine
Less jumping pressure.
Less Accumulator pressure.
Less / more biscuit thickness.
N2 pressure ~ Acc pressure
= 30 kg/cm
2
Shot not effective.
Cold shut
Auto ladle angle variation
Al spill from auto ladle
Cold metal strucjk at nozzle of ladle
Less or more intensification pressure
Loss of Al due to flash from die.



PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 19
Machine
Less jumping pressure.
Less Accumulator pressure.
Less / more biscuit thickness.
N2 pressure ~ Acc pressure


Shot not effective.
Cold shut
30 Kg/cm
2 (
For eg : If Acc pr = 140
N2 pressure should be 110 Kg/cm
2
)


PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 20
Machine
Less 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.

PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 21
Crack
Die
Process
Soldering in die
Bend ejector plate
Machine
Higher metal temperature.
Less die coat spray
More die temperature.
Biscuit catch up in plunger tip
More gate velocity
Less/More dwell time
More jumping pressure.
Improper machine platen
alignment.
Improper side core sliding.
Die opening speed more. .
Man
Material
Less diecoat dilution.
Low Fe content.

Improper coating
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 22
Crack
Die
Soldering in die
Bend ejector plate
Fe content < 0.8 %
No effective water cooling
Near to gate .
Less die coat spray.

PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 23
Crack
Process
Higher metal temperature.
Less die coat spray
More die temperature.
Biscuit catch up in plunger tip
More velocity based on
location.
Less/More dwell time
Temperature indicator not
working.
Variation in topped metal
temperature.
No auto switch - on working.


PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 24
Crack
Process
Higher metal temperature.
Less die coat spray
More die temperature.
Biscuit catch up in plunger tip
More velocity based on
location.
Less/More dwell time
Less spray time
No spray head nozzle focused to
defect
prone area.
Inaccessible area to spray head.



PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 25
Crack
Process
Higher metal temperature.
Less die coat spray
More die temperature.
Biscuit catch up in plunger tip
More velocity based on
location.
Less/More dwell time
Near to gate area.
No effective water cooling
More wall thickness area.

PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 26
Crack
Process
Higher metal temperature.
Less die coat spray
More die temperature.
Biscuit catch up in plunger tip
More gate velocity
Less/More dwell time
No water cooling to plunger
tip and sprue bush
Flash in plunger tip.
No forward stroke of
plunger
to push the biscuit.
Length of the plunger tip
less.
Dragging in sprue bush.

PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 27
Crack
Process
Higher metal temperature.
Less die coat spray
More die temperature.
Biscuit catch up in plunger tip
More gate velocity
Less/More dwell time
More second phase
velocity.

Length of first phase
velocity is below the gate.


PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 28
Crack
Process
Higher metal temperature.
Less die coat spray
More die temperature.
Biscuit catch up in plunger tip
More gate velocity
Less/More dwell time
More T2 timing setting.

More ejection time after die
opening.


PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 29
Crack
Machine
More jumping pressure.

Improper machine platen alignment.

Improper side core sliding.

Die opening speed more.
Worn out Toggle links
Worn out platen shoes.
Fixed die platen flexure.

Set value more
Worn out side core guide ways
Worn out core pull rod

Valve setting more.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 30
Drag
Die
Process
Soldering in die
Rough surface after
die polishing
Under cut in die
Heavy heat check
marks
Machine
Higher metal temperature.
Less die coat spray
More die temperature.
More gate velocity
Less/More dwell time
More jumping pressure.
Improper machine platen
alignment.
Die opening speed more.
.
Man
Material
Less diecoat dilution.
Low Fe content.

Improper coating
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 31
Drag
Process
Higher metal temperature.
Less die coat spray
More die temperature.
More gate velocity
Less/More dwell time
Temperature indicator not
working.
Variation in topped metal
temperature.
No auto switch - on working.


PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 32
Less spray time
No spray head nozzle focused to
defect
prone area.
Inaccessible area to spray head.



Drag
Process
Higher metal temperature.
Less die coat spray
More die temperature.
More gate velocity
Less/More dwell time
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 33
Drag
Process
Higher metal temperature.
Less die coat spray
More die temperature.
More gate velocity
Less/More dwell time
Near to gate area.
No effective water cooling
More wall thickness area.

PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 34
Drag
Process
Higher metal temperature.
Less die coat spray
More die temperature.
More gate velocity
Less/More dwell time
More second phase
velocity.

Length of first phase
velocity is below the gate.


PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 35
Drag
Process
Higher metal temperature.
Less die coat spray
More die temperature.
More gate velocity
Less/More dwell time
More T2 timing setting.

More ejection time after die
opening.


PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 36
Chip off
Die
Process
Catch up in die
Matl projection
in gate.
Machine
Prefilling in Casting.
Low metal temperature.
Ineffective shot
Cold metal from auto ladle
More breaking force
Biscuit catchup in sprue
bush.
Improper trimming.

.
Man
Material
Diecoat matl at gate.

Improper handling of
castings.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 37
Die
Catch up in die
Matl projection
in gate.
Chip off
Less die coat spray
Die chipped off
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 38
Process
Prefilling in Casting.
Low metal temperature.
Ineffective shot
Cold metal from auto ladle
More breaking force
No support in casting
Chip off
First phase velocity ends
beyond the gate
Low die temperature.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 39
Process
Prefilling in Casting.
Low metal temperature.
Ineffective shot
Cold metal from auto ladle
More breaking force

Chip off
More shot delay time
More autoladle waiting time
near shot sleeve
Oxide layer from furnace
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 40
Process
Prefilling in Casting.
Low metal temperature.
Ineffective shot
Cold metal from auto ladle
More breaking force
Chip off
More weight hammer.
Position of holding casting
while breaking.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 41
Process
Prefilling in Casting.
Low metal temperature.
Ineffective shot
Cold metal from auto ladle
More breaking force
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
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 42
Process
Prefilling in Casting.
Low metal temperature.
Ineffective shot
Cold metal from auto ladle
More breaking force
Chip off
Oil in N2 cylinder.
More intensification delay.
Less second phase velocity.

PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 43
Chip off
Machine
Biscuit catchup in sprue
bush.
Improper trimming.
No water cooling to plunger
tip and sprue bush
Flash in plunger tip.
No forward stroke of
plunger
to push the biscuit.
Length of the plunger tip
less.
Dragging in sprue bush.

PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 44
Chip off
Machine
Biscuit 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.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 45
Material
Diecoat matl at gate.

Chip off
Less draft
More drag mark area.
Prone to casting catch up.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 46
Peel off
Die
Process
Flash from the die
Less die
temperature
Die surface
roughness
Machine
Oxide layer from metal
Shot blasting current .
Shot blasting time.
Flow marks .
Fast shot starts from gate.
Improper gate velocity.
Intensifer action improper
More second phase velocity
More intensification delay.

.
Man
Material
Less Cu content

More die coat spray

PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 47
Peel off
Die
Flash from the die
Less die temperature
Die 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.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 48
Peel off
Die
Flash from the die
Less die temperature
Die surface roughness
More water cooling
More die coat spray.
Initial startup.
Waterline opened
after stoppage
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 49
Peel off
Die
Flash from the die
Less die temperature
Die surface roughness
Soldering in die
Die not serviced after taking
corresponding shots.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 50
Peel off
Process
Oxide layer from metal
Shot blasting current .
Shot blasting time.
Flow marks .
Improper gate velocity.
Fast shot starts from gate.
S1 set value more
More first phase velocity.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 51
Peel off
Process
Oxide layer from metal
Shot blasting current
Shot blasting time.
Flow marks .
Improper gate velocity.
Fast shot starts from gate.
Second phase velocity
More intensification pressure
Block in gate due to cold metal.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 52
Peel off
Process
Oxide layer from metal
Shot blasting current .
Shot blasting time.
Flow marks .
Improper gate velocity.
Fast shot starts from gate.
Metal not cleaned properly
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 53
Peel off
Process
Oxide layer from metal
Shot blasting current .
Shot blasting time.
Flow marks .
Improper gate velocity.
Fast shot starts from gate.
Less shots load to impeller
Filter block.
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 54
Peel off
Process
Oxide layer from metal
Shot blasting current .
Shot blasting time.
Improper gate velocity.
Fast shot starts from gate.
Set timing more
Re shot blasting
Flow marks .
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 55
Peel off
Process
Oxide layer from metal
Shot blasting current .
Shot blasting time.
Improper gate velocity.
Fast shot starts from gate.
Flow marks .
Initial startup water line open
PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 56
Machine
Intensifer action improper
More second phase velocity
More intensification delay.

Peel off
Less N2 pressure

PRESSURE DIE CASTING DEFECTS MANUAL
Sheet no : PDCM 57
Machine
Intensifer action improper
More second phase velocity
More intensification delay.

Peel off
Set value more