Is Your Casting Scrap Due to Porosity or Thermal Imbalance?

Answer the five floor-level questions below. The plunger and mold cavity simulator on the right will update in real-time to illustrate your current injection flow physics and defect signatures.

1. What is the visual appearance of the primary scrap defect?

Smooth, round spherical voids on machined faces (gas porosity) Rough, jagged dark cavities at heavy bosses (shrinkage porosity) Linear cracks or incomplete edges along flow lines (cold shuts) Metal build-up or soldering on die corners (die adhesion)

2. When does the defect primarily appear in the production run?

During initial First Out-of-Tool (FOT) trial runs, immediately After 10,000+ continuous shots on the tool insert Randomly mid-shift, often linked to alloy melt deck changes Only when the cycle time is speeded up to hit target volumes

3. What is the measured gate velocity of the molten metal injection?

Under 25 m/s (low flow rate) 30–50 m/s (optimal HPDC range) Over 60 m/s (excessive velocity) We do not measure gate velocity on the press controller

4. How are die temperature and cooling cycles regulated?

Automated conformal cooling lines and thermal sensors Standard internal water lines with manual operator sprays Heavy multi-nozzle spray robots, no thermal camera validation Run dry, manual spray only applied when the part sticks

5. How is shot sleeve plunger transition speed controlled?

Real-time sensor velocity curves and closed-loop hydraulics PQ2 manual calculations, verified monthly Operator adjustments based on visual inspection of the biscuit Machine suffers from accumulator pressure drift

HPDC Injection Simulator Monitor

Flow State: Laminar Injection

The liquid metal wave fills the shot sleeve cleanly. No excessive turbulence or early freezing detected.

Root Cause Analysis

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