145 Stained Castings

Chapter Eighteen
STAINED CASTINGS
145
A. DESCRIPTION AND RECOMMENDED SOLUTIONS
Castings that are stained or discolored are usually castings with black or
dark gray stains. Fig. 18.1 shows a typical stained casting.
This problem almost always involves the application of die or plunger
lubricant. The usual stained or discolored casting has had too much lubri-
cant or the wrong kind of lubricant applied.
It should not be assumed that someone is carelessly applying too
much lubricant. There is usually a reason for the excess. Often it is a
casting that sticks from a worn or heat checked section in the die, which
should be fixed.
Fig. 18.1. Typical stained casting.
146 NADCA DIE CASTING DEFECTS
In aluminum, plunger lubricant is an additional problem. Too much
lubricant will usually stain the castings, regardless of the type of lubricant.
Using too much lubricant is usually a sign that plunger life is being stretched
further than it should be. If this is happening, then there are certain to be
other problems from the lack of pressure by the plunger.
The actions suggested would be as follows:
Review amount of die lubricant being applied, keep this to a minimum
as required for good release and die temperature control, check for
uneven lubricating practices (i.e., one shift applies lubricant heavy, the
other doesnt)
If necessary, review the type of lubricant being used. The die lubri-
cant should match the die operating temperatures measure the die
temperatures and obtain the correct lubricant. Heavy application of
a lubricant intended for a hot die on a cold die will only result in
stained castings and extra porosity, and the lubricant will not do the
job properly
Check the lubricant mixing ratio, make sure it is consistent from shift
to shift an automatic mixer is by far the best
Check the procedures for applying plunger lubricant, look for the prac-
tice of trying to extend tip life by using excessive lubricant try to
minimize this practice by changing tip or sleeve design or just chang-
ing tips as needed
Check for other material in the metal, possibly dirty scrap. If this is the
case, there are likely other metal handling problems