压铸缺陷产生原因及解决方法
Die Casting Defects – Causes and Solutions
第一章表面缺陷solidity
Chapter One
Surface Defects -- Those defects commonly called cold flow or non-fills.
表面缺陷：冷纹、冷隔、激冷层、未充满、涡流纹等
Surface defects: Cold flow, cold lap, chill, non-chill, swirls, etc.
产生原因：金属液流前端温度太低，搭接在一起。
MAIN CAUSE：Metal is frozen when two metal fronts join.
改善措施：
Solutions:
1.提高模具温度
Increase mold temperature
2.减少充型时间
Shorten feeding time
3.改变填充模式（内浇口）
Change feeding way（gate）
4.核查降低金属液温度的原因
Inspect what lowered the metal melts temperature
5.核查压射后期压力过低的原因
Inspect what lowered the injection pressure at the latter phase
6.储压器预置压力过低或者过高
The pressure of the accumulator was set too low or to high
7.料饼太薄
Material cakes are too thin
8.飞边严重
Severe flash
第二章 多层皮
Chapter Two
Laminations -- Defects from layers of metal forming during the process.
多层皮：铸件表面或者内部有明显的多层金属皮
Laminations： Layers of metal inside or outside of casting
产生原因：金属液流动不当等。
MAIN CAUSE：Metal melts flows improperly during the process.
改善措施：
Solutions：
1.检查压铸参数
Inspect the parameter of the die casting machine
2.运用合适的金属流动模式—避免长距离的金属液流动，确保金属液不在离内浇口很远处汇合。
Use the right metal flowing ways, try to avoid long distance metal flowing, and make sure that the metal melts doesn’t join too far away from the gate.
3.调节合适的模具温度，使问题区域的模具温度均匀，最好温度稍高。
Adjust the temperature of the mold; make sure that the temperature of the target area is well-distributed or higher than it should be.
4.合适的增压过程，增压过程要平稳
Stabilize the process of the pressure increasing
5.模具不应该变形（模具可能在增压挠曲—核查模具是否有足够的支撑）
Make sure that the shape of the mold doesn’t change with the increasing of the pressure; inspect if the mold is strong enough to keep its shape with the increasing of the pressure.
 
第三章 气孔
Chapter three
Gas Porosity -- Internal porosity from trapped gas of various kinds.
缺陷：气孔 Gas porosity
产生原因：在充型的过程中气体卷入金属液流而形成的。
MAIN CAUSE: In the feeding process, gas porosity is formed from the gas drawn into the metal melts flow.
改善措施：
Solutions:
1.气体来自于卷入空气、水蒸气或者模具润滑剂产生的气体-核查卷入气体的来源。
Inspect the ways how gas is drawn into the metal melts flow or inspect whether the gas is from the air, the steam, the mold lubricant etc.
2.核查内浇道以保证金属液平稳流动。
Inspect the gate to make sure the steady flow of metal melts.
3.检查排气孔。
Inspect the exhaust vent.
4.保证真空系统正常工作。
Assure the proper functioning of vacuum system
5.核查来自于润滑剂的气体。
Inspect the gas from the mold lubricant.
6.核查水汽（模具上的水）
Inspect the water vapor, especially the water in the mold.
第四章气泡
Chapter four
Blisters -- Surface manifestation of trapped gas.
缺陷：气泡（Blisters）
产生原因：在充型的过程中卷入金属液的气体在铸件表皮下形成的泡。
MAIN CAUSE:  In the feeding process, blisters are formed from
改善措施：
MAIN CAUSE:
1.气泡是气孔的另外一种表现形式，因此，针对气孔的改善措施同样也使用与气泡。如：减少卷入空气或改善排气和真空系统问题。
Blister is just another form of gas porosity. Therefore, its solutions are similar to those of gas porosity. For example, we can decrease the gas from the air or better the exhaust vent and vacuum system.
2.解决气泡问题最根本方法时解决气孔问题，然而，作为一种暂时性的解决方法，可通过喷雾冷却产生气泡的部位。
The essential solution is to solve the shrinkage porosity problem. However, as a temporary solution, we can cool down the target area by mist spray.
3.取出铸件后立刻猝水冷却（这种方式可以提高铸件表面强度从而阻止气泡形成）。
Cool down the castings immediately after taking out, which can improve the intensity of the casting surface and prevent blisters.
4.降低金属液温度（但应注意是否产生其他问题）
Lower the metal melts temperature and pay attention the others problems it will produce.
第五章 流体间隙
Chapter 5
Flow Porosity --Surface or internal porosity from poor pressure conditions
流体间隙
Flow porosity
产生原因
MAIN CAUSE
金属液流动过慢，温度过低或者流动模式不当，在凝固的金属液流之间产生间隙（孔洞）。
Surface or internal porosity caused by poor flowing conditions or low temperatures of the metal melts.
改善措施
Solutions
1.流体间隙是一种金属液流动产生的缺陷，所以前面提到的解决表面缺陷的改善措施也适用于改善流体间隙的缺陷
Flow porosity is a defect that caused by poor flowing conditions of the metal melts. So the solutions for the surface defects can also be applied to solve flow porosity.
2.金属液之间的间隙可能出现在铸件的表面（空穴），也可能存在于铸件的内部（孔洞），稳定熔炉操作（降低炉温的波动，最大波动应该小于+/-5.6°C），采用修正后的金属温度
The gaps occurred during the process of die casting can be on the surface of the casting, which are called cavitations, or inside of the casting, which are called holes.
Stabilize the temperature of the furnace, keep the right temperature and keep the tolerance to be within +/- 5.6°C.
3.稳定模具温度，采取较高的模具温度（大于204.4°C）
Stabilize the temperature of the mold, and use a relatively higher temperature ( higher than 204.4°C) for the mold.

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