Aiming for seizure-free aluminum die casting

Soldering refers to the phenomenon in the aluminum die casting process where molten aluminum adheres to the surface of the mold. This phenomenon is a significant challenge that greatly impacts the productivity and quality of die casting. Soldering in aluminum die casting is a critical issue that significantly affects product quality and production efficiency. In the aluminum die casting process, uneven mold temperature, improper use of release agents, and defective mold material or surface treatment can cause soldering. When soldering occurs, surface defects appear on the product, and production efficiency also decreases. Our company minimizes the occurrence of soldering by selecting the optimal release agent and utilizing spray robots for aluminum die casting soldering prevention. This allows us to maintain high quality in our aluminum die casting products and stably provide products that have resolved soldering issues.
【Main Causes of Soldering in Aluminum Die Casting】
・Uneven Temperature
If the temperature control of the die casting mold is insufficient, aluminum tends to abnormally adhere to the mold surface during melting, leading to soldering.
・Improper Use of Release Agent
If the release agent is inappropriate or insufficient in quantity, the product adheres tightly to the mold, making removal difficult, and soldering occurs.
・Mold Material and Surface Treatment Issues
If the surface treatment of the die casting mold itself is not appropriate, friction and adhesion between aluminum and the mold occur, leading to soldering.
When soldering occurs in the aluminum die casting process, the following problems arise:
Reduced Product Quality: Surface defects occur in the finished product, leading to performance degradation in its final application. This becomes a critical defect, especially in fields requiring high precision, such as automotive parts and electronic control components.
Decreased Production Efficiency: The frequent need to remove aluminum adhering to the mold can significantly reduce production speed.
Shortened Mold Lifespan: If the mold is damaged by soldering, new mold fabrication becomes necessary, increasing costs.
To minimize the occurrence of soldering in aluminum die casting, our company thoroughly implements the following countermeasures:
Selection of Optimal Release Agent and Utilization of Spray Robots
By selecting a release agent suitable for the product and process conditions and performing uniform application with spray robots, we prevent excessive adhesion of molten aluminum to the mold. Furthermore, the fine mist spray from the spray robots enhances cooling efficiency, improving mold durability.
Regular Mold Maintenance
By performing regular mold maintenance and inspecting accumulated aluminum and undercut areas, we prevent soldering and other issues.
Adoption of Hard Coating (Tungsten Coating)
By applying tungsten coating to the mold surface, we improve wear resistance and heat resistance, further enhancing the soldering prevention effect.
Continuous Improvement of Production Process
We constantly review our production processes, identify factors prone to soldering, and implement appropriate measures to maintain a stable production system.
Through these soldering prevention measures, our aluminum die casting products maintain high quality and excel in durability and functionality. We have earned significant trust in applications requiring high precision and durability, such as in the automotive industry.
【Features of Yamaguchi's Aluminum Die Casting】
Our aluminum die casting technology has the following features:
・Equipped with die casting machines ranging from 420t to 800t, we meet a wide range of manufacturing needs.
・Capable of handling product weights up to 6.5 kg.
・Approximately 65,000 products are manufactured monthly.
・We consistently perform precision machining after casting in our own factory, achieving high quality and short lead times.
Soldering is a critical issue that significantly impacts quality and productivity in aluminum die casting. Our company minimizes the occurrence of soldering by thoroughly implementing the selection of optimal release agents, utilization of spray robots, regular mold maintenance, adoption of hard coatings, and continuous improvement of production processes.
Through these measures, our aluminum die casting products achieve high quality, excellent durability, and stable performance, earning significant trust in fields requiring high precision and durability, such as the automotive industry.
We will continue to strive for technological innovation and quality improvement to provide customers with even higher-performance aluminum die casting products.