ALUMINUM ZINC DIE CASTING Casting Porosity（铝和锌压铸铸件孔隙度）.pdf

ALUMINUM ZINC DIE CASTING Casting Porosity INTRODUCTION Porosity in castings is a fairly common complaint of casting users and heightens customer concerns about part reliability and quality. Although porosity is inherent in all castings, the solution is to control the porosity which in turn depends on understanding and determining its sources. POROSITY Porosity in a casting is air entrapment during solidification. It is usually necessary to address porosity when specifying die castings. Minimizing porosity begins with up-front planning in the design of the part and die casting die and control during the casting process. Sophisticated process control and monitoring equipment as well as simulation software is best utilized for castings with stringent porosity requirements. If specific porosity will be detrimental to the use of the product being cast, the die caster must be informed of the areas that will require special control to reduce the incidence of such porosity. This information must be supplied in detail at the time of the RFQ, so that measures such as part design change requests, accountability for higher scrap or utilization of special processes, can be taken in advance of die design and construction. The skin, which has a finer grain structure, begins at each surface and extends inward to a typical thickness of .015 to .020 in. The finer grain structure and relative absence of porosity give the skin superior mechanical properties. The removal of the skin to a depth greater than Page 1 of 3 .015 in. by secondary processes, such as machining, increases the chance of exposing porosity. These important points are not widely recognized by designers. The as-cast surface or skin is more dense than the core, so removal by machining should be minimized. The die caster should be aware of critical areas as porosity can be managed to a large extent via gating, overflows, vacuum-assist including