Die casting hot joints are silent quality killers in metal forming—they arise from local cooling delays in castings and trigger a chain of defects, from surface dimples to catastrophic fatigue failure. For manufacturers producing critical parts (e.g., automotive brake calipers, hydraulic valves), ignoring hot joints can lead to costly recalls, production halts, and reputational damage. […]
Gravity die casting (also known as permanent mold casting) is a pivotal metal-forming process that relies on the natural force of gravity to fill mold cavities with molten metal. Unlike high-pressure die casting, it avoids complex pressure systems, making it a cost-effective and reliable choice for specific industrial scenarios—especially for thick-walled parts requiring heat treatment
Aluminum shell die casting is a cornerstone process in manufacturing lightweight, durable enclosures for electronics, automotive components, and industrial equipment. Unlike solid aluminum parts, aluminum shells require precise control over wall thickness, surface finish, and structural integrity—even small defects like porosity or warping can render the shell unusable (e.g., compromising waterproofing for phone casings or
Pouring (gravity casting) and die casting are two foundational metal-forming processes, each optimized for distinct production needs. While pouring relies on the natural force of gravity to fill molds, die casting uses high pressure to inject molten metal at high speed—these core differences shape their performance, cost, and application scenarios. For manufacturers, choosing the wrong
Integrated die casting, a game-changing technology in manufacturing—especially for the automotive industry—redefines how complex components are produced. By merging dozens to hundreds of traditional stamped and welded parts into a single, seamless component via super-large die casting machines, it addresses long-standing pain points like low production efficiency, high assembly costs, and heavy part weights. However,
Gas-assisted die casting (GADC) is a revolutionary advancement in metal forming that addresses key limitations of traditional die casting. By integrating high-pressure inert gas (typically nitrogen) into the casting process, it creates hollow structures or functional channels within parts—opening new possibilities for lightweight, complex, and high-performance components. For manufacturers struggling with material waste, design constraints,
The minimum thinnest wall thickness of aluminum alloy die casting is a critical design parameter—too thin, and you risk defects like undercasting or cold barriers; too thick, and you waste material and increase production time. While technical breakthroughs have pushed the limits of how thin aluminum die cast parts can be, there’s no one-size-fits-all answer.
The die casting runner system is the “vascular network” of the die casting process—without a well-designed system, molten metal cannot flow smoothly into the mold cavity, leading to defects like cold shuts, porosity, or undercasting. As the only channel connecting the injection device to the mold cavity, it directly impacts production efficiency, part quality, and
Die casting coils, a critical internal defect in the die casting process, severely undermines the mechanical performance and reliability of castings. Unlike surface flaws like scratches or burrs, this defect hides inside castings, often only detectable through non-destructive testing (such as X-rays). Its core is the entrainment of air or gas into the molten metal
The die casting injection process is a precisely orchestrated sequence of speed and pressure adjustments that transforms molten metal into high-quality parts. While it may seem like a single “injection” step, it actually unfolds in distinct stages—each designed to solve a specific challenge, from expelling air to preventing defects like shrinkage or flash. These stages
Die casting product sink—also called dent or shrinkage depression—is a prevalent surface defect characterized by smooth, sunken areas (0.1–2mm deep) that form in thick-walled sections of cast parts. It not only ruins product aesthetics (rejecting 5–8% of parts in mass production) but also weakens structural integrity: sinks in pressure-bearing components (e.g., hydraulic valves) can cause
Shrinkage cracking is one of the most destructive defects in aluminum alloy die casting—manifesting as thin, linear cracks that often penetrate the entire part. Unlike surface blemishes (e.g., pockmarks) that affect aesthetics, shrinkage cracking directly compromises structural integrity: parts with such cracks may fail under load, leading to safety hazards (e.g., automotive component failure) or
Semi-solid die casting (SSDC) is an advanced metal-forming technology that bridges the gap between traditional casting and forging—redefining how high-performance metal parts are made. Unlike conventional die casting (which uses fully molten metal) or forging (which relies on solid metal deformation), SSDC leverages metal in a semi-solid state (50–90% solid fraction) to create parts with
Aluminum die casting is widely used in automotive, electronics, and aerospace industries due to its lightweight, high strength, and cost-effectiveness. However, the process involves multiple complex links—from material selection to post-treatment—and any oversight can lead to defects like porosity, cracks, or undercasting. To ensure stable production and high-quality aluminum parts, manufacturers must master critical precautions
In metal forming, precision casting and die casting are two core processes, each tailored to distinct production needs. Precision casting excels at creating complex, high-performance parts in small batches, while die casting dominates mass production of lightweight, thin-walled components. For manufacturers, choosing the wrong process can lead to wasted costs, delayed projects, or subpar product
Die casting clip is a typical surface defect in the die casting process, which seriously affects the appearance quality and structural integrity of castings. It is mainly manifested as obvious delamination or peeling on the casting surface—these defects not only reduce the product’s market competitiveness but may also cause safety hazards in high-precision application scenarios
