1. Cold Shut

A cold shut is a common casting defect where two or more streams of molten metal fail to merge properly, resulting in an incompletely formed casting. This defect is caused by a variety of reasons, such as insufficient molten metal temperature, improper gate or runner design, or too fast an injection speed. When the molten metal is not fully fused, it causes visible lines or gaps on the surface of the casting, affecting its structural integrity and aesthetics.

2. Porosity

Porosity is a common defect in die casting, characterized by the presence of small voids or air pockets in the cast material. These voids vary in size and distribution, and they can significantly affect the mechanical properties and structural integrity of the casting.

Porosity is caused by a variety of factors, including:

Gas entrapment

Uneven cooling or shrinkage

High melt temperature

Improper gating and venting

3. Shrinkage

Shrinkage is a common casting defect characterized by voids or discontinuities in the casting due to insufficient material flow and solidification. This occurs when the molten metal loses volume during cooling and solidification.

Shrinkage defects can be caused by a variety of reasons, including:

Insufficient feed metal

Improper cooling rate

Alloy composition

4. Flash

Flash is a common defect in die casting characterized by thin, unwanted metal protrusions or flash on the surface of the casting. This occurs when molten metal escapes from the mold cavity through a small gap or space between the mold halves or other mating surfaces.

Flash defects can occur during casting due to a variety of reasons, including:

Improper mold closure

High injection pressures

Poor mold maintenance

5. Gas Porosity

Porosity is a common defect in die casting characterized by the presence of gas-filled voids or bubbles within the cast material. These voids vary in size and distribution and can negatively affect the mechanical properties and structural integrity of the casting.

Gas porosity is caused by a variety of factors, including:

Trapped air

Dissolved gases

Moisture content