In this new era of structural aluminum die castings and the mechanical property requirements which necessitate their use, certain aspects of the die casting process and the resulting product require a higher level of attention than they did in traditional cast to shape applications. One such item is the potential creation of “cold flakes” and the following issue of these discontinuities entering the casting itself. Cold flakes, also referred to as externally solidified products, are metal which solidifies in the shot sleeve prior to injection, are broken from the sleeve wall, and washed along by the injected liquid alloy. Shrinkage porosity, cold flow, oxide films, and unpredictable flow patterns can also be caused by cold flakes and have a detrimental impact on mechanical properties. Given its random nature and infrequent recognition, a true corrective action is difficult to implement and validate. This webinar reviews our understanding of how and where cold flakes form, their effects on casting quality, and what measures can be taken in a traditional process to minimize their impact on casting performance.
Certification Level: Level II Process
Date of Presentation: 1/06/16
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