Low-Pressure Die Casting Defects: Root Causes & Preventive Strategies by Tiegu Foundry

At Tiegu Foundry, we combine 25+ years of precision casting expertise with advanced low-pressure die casting technology to deliver defect-free components. This guide outlines common casting flaws, their origins, and our ISO 9001-certified solutions to help manufacturers enhance product reliability.

Key Defect Categories & Solutions

Defect Type

Characteristics

Tiegu’s Recommended Solutions

Internal Defects Analysis

1. Inclusions

• Use certified ASTM B85 alloy materials

• Implement dual-stage degassing process

• Conduct spectrometric analysis before casting

• Causes: Impurities in raw materials or improper degassing.

• Tiegu’s Approach:

2. Gas Porosity

• Optimize gating system with 3D flow simulation

• Maintain melt temperature within 680-720°C (±5°C)

• Apply vacuum-assisted casting for critical parts

• Causes: Trapped air during filling or hydrogen absorption.

• Mitigation:

Surface Defects Prevention

1. Blisters

• Install thermocouples for real-time die temperature monitoring (200-250°C for Al alloys)

• Use water-based environmentally friendly release agents

• Root Cause: Uneven die cooling or residual moisture.

• Tiegu’s Solution:

2. Cold Laps

• Preheat dies to 150-200°C for aluminum alloys

• Increase filling velocity by 15-20%

• Causes: Insufficient melt fluidity during filling.

• Resolution:

Advanced Prevention Techniques

1. Digital Process Control

• Deploy THERCAST® simulation software to predict defects

• Monitor pressure curves with ±0.5 bar accuracy

2. Material Engineering

• Custom alloys (e.g., Al-Si-Mg with Fe <0.8%)

• Heat treatment optimization for stress relief

3. Continuous Improvement

• Track defect patterns using Six Sigma methodology

• Conduct quarterly mold maintenance audits

Industry Standards & Innovations

• Compliance: ISO 9001:2015, IATF 16949:2016

• Latest Developments:

• AI-driven defect prediction algorithms

• Laser surface alloying for enhanced wear resistance

Conclusion
Tiegu Foundry’s comprehensive approach reduces scrap rates to <1.5% while maintaining tight dimensional tolerances (±0.1mm). Our solutions meet global standards and deliver components for automotive, aerospace, and industrial applications.

Partner with Tiegu for:
✅ Custom alloy development
✅ Real-time pressure monitoring
✅ End-to-end casting solutions

Contact us today at zbw@tiegu.net or visit www.tieguexport.com to discuss your requirements.