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140 NADCA DIE CASTING DEFECTS

Chapter Seventeen
FLASH
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Fig. 17.1 Examples of flash with different levels of severity.
A. DESCRIPTION OF THE PROBLEM
Flash could be described as when liquid metal flows into an area on the die
where it is not expected, such as the parting line, under a slide, along side
an ejector pin, etc. (Fig. 17.1).
Flash is a serious operational problem with die castings; it limits the
ability of die casters to use the full capabilities of the process in different
pressure and temperature settings to make better castings.
B. CAUSES
In general, flash is caused by high metal temperatures, mechanical consid-
erations of the machine or the die (poor die fit or uneven machine locking
pressures), improper calculations of the machine pressures, or just plain
wear and tear on the die and the machines.
141 Flash
The metal temperature question should be easily settled as noted be-
low, and then the issue becomes: is it the die or the machine? This argu-
ment often becomes a permanent skirmish and is never settled. The engi-
neering calculations for the metal pressures are quickly done, but should
be reviewed. One way to get these issues settled is to follow the step-by-
step procedure as discussed below.
C. METAL TEMPERATURES
Metal temperatures should be reviewed first. They should be in the normal
operating range, which would be about as follows for the usual alloys:
Zinc 800 F (426 C) 5 F (3 C)
Aluminum 1200 F (650 C) to 1250 F (675 C) ( 10 F (6 C))
Magnesium 1200 F (650 C) to 1250 F (675 C) ( 10 F (6 C))
If higher temperatures are required, check the process design factors (gate
area, fill time, gate velocity, metal pressure, flow pattern, etc.) to be sure
they are correct. Very often a higher metal temperature is used to make up
for design deficiency in one of the other process factors. Sometimes a
higher temperature is acceptable, but it should be an unusual exception to
the normal setting.
A typical metal temperature problem lies not so much in the set-
ting, but rather in maintaining a stable operating condition. A tempera-
ture controller or operating procedure that occasionally allows high tem-
peratures can be a real problem in creating flash, especially in an
automatic operation.
D. OPERATIONAL FACTORS
MACHINE LOCKING PROBLEMS
The next step would be to use a squaring block, a new die, or a known
square die on the machine to balance the tie bar loads. Each tie bar should
be set to take the same load using some method of measuring tie bar strain
when the square block is installed. This should eliminate any unbalance in
the tie bar adjustments.
These other factors affecting machine setup should be reviewed one
at a time:
142 NADCA DIE CASTING DEFECTS
General condition of the machine:
Toggle links not worn
Tie bar bushings not excessively worn
Platens flat, not bent or rough
Tie bar nuts not loose
Moveable platen shoes adjusted correctly
Die is set up correctly
Die carrier in use and adjusted correctly
E. METAL PRESSURE QUESTIONS
Metal pressure should be reviewed. Static metal pressure is important,
as is impact pressure and intensified pressure. The approximate suggested
static metal pressure minimums were presented in the shrink porosity
section, and are presented again with suggested maximums (Table 17.1).
The maximums are not necessary for part quality, but are important for
flash reduction.
The maximums are approximate, and are intended to provide some
guidance as to typical values. Each die caster should be capable of select-
ing the value that is best for their parts and their operation. For example, it
is usually counter productive to run a small plunger tip to get a high per-
cent fill if it also pushes the static pressure too high and causes too many
operational problems from flash.
It is best to keep to the lower end of these values to minimize flash.
The impact spike will vary from machine to machine, but the biggest
single factor influencing the size of the impact spike is whether the shot
accumulator is in the back of the machine or in the front. An accumulator
in the back can easily double the impact spike.
Various operational procedures are used to reduce the impact flash.
These typically include: delay the onset of fast shot, decrease the fast shot
speed, reduce the metal temperature (or delay the shot with the metal in the
static
pressure
approximate
maximum
intensified
pressure
approximate
maximum
Aluminum 3,000 psi 5500 psi 8,000 psi 15,000 psi
Zinc 2,000 psi 4000 psi NADCA NADCA
Magnesium 3,000 psi 4000 psi 8,000 psi 12,000 psi
Table 17.1. Static pressures minimums and maximums.
143 Flash
sleeve), reduce the shot accumulator nitrogen pressure, etc. All these tac-
tics can seriously impact part quality, even if not apparent in the casting
appearance at the operators station. It is critical for good defect control
that these types of solutions for flash dont dominate the machine settings.
Sometimes these types of adjustments are the appropriate choice, but
they should be used only after verifying that there are no other detrimental
effects. If necessary for good casting quality to run with a setting that
increases flash, the process technician may be required to find another way
to reduce flash and not leave it as an optional machine adjustment.
The low impact control on some machines is a very valuable option
if it can be made to work properly.
F. DIE SEALING PROBLEMS
Most dies are made to fit quite well at room temperature. The problem
with incorrect die fit occurs when the die is at operating temperature.
At this point the die will be heated unevenly from the casting process
(most of the heat is usually in the center of the insert), causing the die
to expand unevenly.
As the die expands unevenly, the die doesnt fit as it did in the tool
room at 75 F, and flash develops. This is not difficult to correct if the
die has a flat parting line, but if the parting line is stepped and there are
slides involved, it becomes quite difficult to predict the die shape at oper-
ating temperature.
A very important consideration in die expansion is proper thermal
analysis and cooling system location in the die. This is best done with a
computer analysis, which will not only pay for itself in increased cycle
time, but will help in reducing flash by keeping the die temperature even.
It is especially important that hot areas in the biscuit and sprue areas are
properly cooled.
In operation, it is often necessary to check the die fit by bluing the die
at operating temperature. This is usually done just before the die is sched-
uled to come off. The die should continue to be run steadily to be sure it is
at operating temperature. Then it should be stopped, water turned off, the
die cleaned, and bluing applied. The die faces should be touched as fast as
possible. This will capture the high spots and provide reference informa-
tion for the tool room. Without this approach, it is difficult to know just
what the die shape is when it is hot.
Good die maintenance is critical for minimal flash. It is imperative to
take some action when flash first appears. Continuing to run when flash
144 NADCA DIE CASTING DEFECTS
accumulates guarantees an indented die face, with continued flash on that
die. If the engineering was done correctly, then there should be some ap-
propriate action available when flash starts. That is, if the design is correct
but flash still starts to build up, then there must be some operational factor
that needs to be corrected.
One die design issue is the location of the center of the opening force
when the die is on the machine. This opening force should be centered on
the machine so that the opening force generated by the metal pressure in
the die is as centered as possible. This makes the tie bar load even and is
key to preventing flash. The tie bar load should be calculated before the
location of the parts in the die is established. If this is done, it will also
confirm whether the die will run properly on the selected machine.

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