Flash Defects: A Guide to Correcting the Problems

Flashing is when metal escapes the die cavity within the die casting process. In other words, it happens when metal goes where it is not designed to go. Reducing flash problems can be very frustrating and time consuming for die casting companies and more specifically operators, technicians and engineers.

Solutions to flash problems are described in detail in NADCA’s Flash Defects publication. This new book provides information on how to determine the root cause of a flashing problem. Corrective measures as well as information on preventing flash are found in sections of the publication on how to design and maintain a die to minimize flashing, how to maintain the machine to minimize flashing, and how to reduce flashing using the impact force equation. This easy-to-read concise document is a valuable resource for any die casting operation.

 

TABLE OF CONTENTS

Flash Defects Outline

1.          What is flashing in the die casting process?

2.          Why does flashing occur?

3.          How do you determine the root cause of a flashing problem?

4.          How do you design and maintain a die to minimize flashing?

  1. Die squareness 
  2. Thermal aspects of die design
  3. Die seal off
  4. Centering of the part within the die
  5. Wear plate and lock design
  6. New technology in flash control

5.          How do you maintain the machine to minimize flashing?

  1. Evaluating machine squareness
  2. Machine clamp end linkage components
  3. Machine clamp end hydraulics
  4. Machine platen surfaces

6.          How do you determine impact force?

  1. Static force
  2. Kinetic force
  3. Projected Area Calculation

7.          How do you reduce flashing using the impact force equation?

  1. Plunger tip size
  2. Machine inertia
  3. Accumulator pressure
  4. Intensifier trigger position and rise time

8.          Conclusions