High Pressure Die Casting Processes: The Difficulties

It is rather a daunting task for the casting designers and engineers to create stability in high pressure die-casting processes. Within approximately hundred casting process parameters, it is very difficult to identify and acknowledge the variation of each of the parameters on the final casting quality. The biggest challenge for the engineers and designers remain the counter effect of a single parameter on the rest of the other parameters and then how that collective variations effect the final casting.

The issue becomes all the more difficult as the continuous changes in variables and parameter variations can reflect alterations in the various stages of moulding, production run and casting. Though advanced monitoring systems do indicate the production floor regarding the parameters being out of control, but of course they cannot keep a track of how changing parameters would effect the other parameters and the quality of the final product.

For understanding the complete effect of these changes in individual form and concert, the engineers would be required to develop experiments on the shop floor to study parameter variables and their corresponding results on the final product. No wonder it is an expensive and time consuming process to implement corrections or do a basic reassessment of the permutations.

By using the latest or the state of the art computer hardware and appropriate stimulation program, engineers can be well abreast with the point to point information regarding the high-pressure die casting process during the early stages of process development rather than during production when the stimulation is ignored completely.

Prior to the fabrication implementation, the different casting processes can be optimized, the crucial dependencies and alterations can be identified in advance and corrective measures can be applied then and there itself. With so much of information and prior indications, a better quality of castings can be produced.

Find out more at Casting Processes.