Internal Porosity and Shrinkage
Porosity and localized shrinkage occurred in thick sections and machining areas, creating a risk of internal defects becoming exposed after CNC machining.
Automotive & Motorcycle Industry
Automotive Aluminum Die Casting
Mass Production Improvement Case Study
Through tooling design review, molten aluminum quality management, die temperature control, die casting parameter optimization, and quality validation, EX Die Casting helped the customer reduce internal casting defects and dimensional variation while establishing a stable and traceable mass production process.
INDUSTRYAutomotive & Motorcycle Components
01
PROJECT OVERVIEW
Project Background
Automotive and motorcycle components must withstand continuous vibration, impact, temperature fluctuations, and long-term operation. Structural strength, dimensional accuracy, and consistent production quality are therefore essential requirements.
The component in this project featured reinforcing ribs, threaded holes, machining datum surfaces, and localized thick sections. During initial production, porosity, localized shrinkage, and dimensional variation were identified in several critical areas.
These issues increased the quality risks associated with subsequent CNC machining, dimensional inspection, and final assembly. EX Die Casting therefore conducted an integrated review of the product design, tooling configuration, molten aluminum quality, die casting conditions, and inspection controls.
IndustryAutomotive & Motorcycle Components
ProcessAluminum High Pressure Die Casting
Primary FocusInternal Quality and Dimensional Stability
Secondary ProcessCNC Machining and Assembly
Quality VerificationX-ray Inspection and CMM Measurement
02
CUSTOMER CHALLENGES
Key Production Challenges
Dimensional Instability
Variations in die temperature and casting conditions affected critical hole positions, flatness, and machining datum dimensions.
CNC Machining Risk
Unstable casting dimensions and internal quality increased the likelihood of machining deviation, hole-position errors, rework, and production losses.
Limited Process Traceability
Molten aluminum conditions, die temperatures, casting parameters, and inspection records required further integration to improve root-cause analysis and traceability.
03
OUR SOLUTION
EX Die Casting Improvement Plan
01
Tooling and Runner System Review
The engineering team reviewed the product geometry, gate locations, runner configuration, overflow design, venting system, biscuit thickness, and ejector arrangement.
These improvements optimized molten aluminum flow through the cavity and provided more effective air evacuation during filling.
02
Molten Aluminum Quality Management
Degassing and dross removal equipment was used to reduce dissolved gas, oxides, and inclusions within the molten aluminum.
A Reduced Pressure Test (RPT) was also performed to evaluate molten aluminum quality after the degassing process.
03
Die Temperature and Casting Parameter Control
Injection speed, intensification pressure, molten aluminum temperature, die temperature, and cooling time were reviewed and optimized.
An infrared thermal imaging camera was used to monitor die temperature distribution and identify localized overheating or excessive temperature differences.
04
Internal Quality and Dimensional Verification
An industrial X-ray inspection system was used to perform non-destructive testing and identify internal porosity, shrinkage, and other hidden casting defects.
Critical hole positions, positional tolerances, flatness, and machining datum surfaces were verified using a Coordinate Measuring Machine (CMM).
04
QUALITY CONTROL
Integrated Mass Production Quality Control
01
Molten Aluminum Control
Control of melt temperature, degassing conditions, gas content, oxides, and inclusions.
02
Die Temperature Control
Monitoring of die temperature distribution and thermal balance throughout the production cycle.
03
First Article Inspection
First Article Inspection (FAI) confirms product dimensions and quality before mass production begins.
04
In-Process Inspection
In-Process Quality Control (IPQC) identifies dimensional and process abnormalities during production.
05
X-ray Inspection
Non-destructive inspection identifies internal porosity, shrinkage, and other hidden casting defects.
06
Dimensional Verification
Critical dimensions, geometric tolerances, and machining datum stability are verified before shipment.
05
PROJECT RESULTS
Improvement Results
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Reduced Internal Casting Defects
Improvements to molten aluminum quality, die venting, and casting parameters reduced the risk of porosity, shrinkage, and defect exposure after machining.
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Improved Dimensional Consistency
Better thermal balance and more stable casting parameters improved the consistency of critical holes, flatness, and machining datum surfaces.
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Lower CNC Machining Risk
More stable casting dimensions and internal quality reduced machining deviation, hole-position errors, rework, and potential scrap.
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Improved Process Traceability
Molten aluminum records, die temperature data, casting parameters, X-ray results, and dimensional inspection records were integrated into the production controls.
KEY RESULT
The objective of this project was not limited to correcting a single casting defect. EX Die Casting established an integrated quality management system covering molten aluminum quality, die temperature, casting parameters, internal inspection, and dimensional verification.
06
INTEGRATED MANUFACTURING
From Product Development to Stable Mass Production
High-Complexity Die Casting
× Flexible Manufacturing
× Fully Integrated Production
Stable aluminum die casting quality requires the coordinated management of product design, tooling structure, alloy properties, casting conditions, secondary operations, and quality inspection.
EX Die Casting provides integrated manufacturing services covering Design for Manufacturability (DFM), tooling development, aluminum high-pressure die casting, CNC machining, surface finishing, quality inspection, packing, and shipment.
Through cross-process integration and data-driven quality management, we help customers reduce product development risk, shorten mass production lead time, and improve product consistency and reliability.
START YOUR PROJECT
Developing a New
Aluminum Die Casting Component?
Please provide your estimated annual demand, 2D drawings, 3D models, material specifications, and quality requirements. EX Die Casting will evaluate the product structure and application conditions and provide professional recommendations for tooling, die casting, machining, inspection, and mass production.
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