In die casting, quality assurance is of paramount importance. Die casting product testing is a step in the process that you cannot ignore. There are many ways that die castings may fail. If these failures are allowed to slip away, it may cause disastrous consequences to your finished product. There must be an effective quality control program to test all possible failure events that die casting parts may experience.

The possibility of die casting failure includes:

1. Porosity

Porosity refers to the state when bubbles are trapped in the part during the die casting process. Usually some tiny voids will inevitably appear, but too many tiny voids or some larger voids will greatly weaken the integrity of the final part and cause it to collapse under pressure.

Quality assurance professionals usually use X-ray techniques or destructive testing to test porosity. The correct casting technique should prevent catastrophic blowholes. Therefore, it is important to make every effort to avoid excessive blowholes by using good process control during the die casting process. However, testing the finished product for faults helps ensure the highest quality product.

2. Incorrect appearance

It is very important to establish visual standards for the surface appearance of castings. This is usually done in the early stages of product development with the customer before the mold design. There are many reasons that the appearance of a work may be incorrect. The most obvious is usually the need for reassembly or poor casting process control.

The only real way to understand the appearance of a part is to compare the actual cast surface with the visual standard established by the customer. If the casting is highly decorative, the die casting machine must understand the customer's surface finish requirements, and then formulate written decorative standards for the quality team to use in production.

3. Size issues

Due to mold wear or offset between mold halves, some parts may not meet the expected size. These size problems may be so small that they cannot be detected with the naked eye, but they may still cause problems later. The critical dimensions must be indicated on the part printing and checked together with the die-casting machine during the product development process to ensure that the die-casting machine can meet the dimensional tolerances. Critical dimensions always need to be measured by the quality team during the casting process. Measurements can be very simple, or sometimes they require special gauges for very special dimensions on die castings.

If you often encounter size problems or lack of repeatability, you may want to consider repairing the mold or reinstalling the mold.

4. Omit painting or assembly steps

As with appearance issues, the only real way to tell if it was missed in finishing or assembly is to look at the part. These types of problems are almost always the result of incorrect procedures. Writing a clear process and checklist can help avoid this problem. A good die casting machine will have a system that can track parts throughout the production process of the factory and provide very clear inspection standards for each station of the process.

5. Casting leakage

Castings can leak for a variety of reasons, including porosity and mold wear. To test whether the casting is leaking, an air attenuation leak tester is usually used. Another way to check for leaks is to immerse the part in water for a specified time and pressure. Customers need to define this method during product release and before mold design.

6. Organize the problem

If you leave excess material, it may be a problem of poor die casting maintenance, poor design or poor finishing process. Although you can also use online gauges or p-frame methods to test for more subtle trimming issues, it is usually easy to see if there are trimming issues.

Why quality assurance is important
It will be effective if you take the time to properly conduct product quality assurance testing. This is very important because it can help you avoid sending defective parts to customers. Damaged parts can cause customer production delays, excess costs, property damage and personal injury, and may also damage your reputation.

Quality assurance can also help you identify areas in the process that can be simplified and improved in order to continuously produce better products.

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