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МнениеПубликувано на: Вто Ное 16, 2021 6:54 pm 

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In order to perform die casting, special equipment is required due to the high corrosive and high heat generated during the process. It is necessary to maintain the temperature of molten aluminum at 1,100 degrees Fahrenheit/593 degrees Celsius, the temperature of molten magnesium at 1,250 degrees Fahrenheit/677 degrees Celsius, and the temperature of the die at 350 degrees Fahrenheit/177 degrees Celsius. Die soldering (also known as die sticking), which is a problem that occurs in the zinc castings industry, is one of the most significant and persistent issues that die casters must deal with on a regular basis. Die soldering (also known as die sticking) is a problem that occurs in the cnc machining industry. Observations have revealed that when molten metal is brought into contact with the surface of a die or die component, the steel is heated above its soldering critical temperature, causing iron to dissolve into the melt while, at the same time, molten metal diffuses into the die surface, resulting in the formation of a layer of intermetallics at the interface between the two metals.

https://www.youtube.com/watch?v=ppu41tOVBHQ&t=87sA common complaint among die casters is that corrosion caused by die soldering (also known as die sticking) is one of the most persistent problems they've encountered in their work. When molten metal welds to the surface of an extrusion die, it is known as die soldering (also known as die sticking). This results in part sticking, tool and component damage (including the die), and a poor surface finish on the part. Casters must frequently stop their processes in order to clean the die and its components, and some of the components must be replaced on a regular basis in order to resolve the problem. As a result, increased costs and scrap rates are experienced, as well as a loss of process and shot-size stability, as well as a higher overall cost of quality, to name a few outcomes. Aside from that, die casters must maintain large inventories of spare parts to be ready for any unexpected emergencies.

This layer thickens and becomes increasingly thick over time as it accumulates more and more debris. The molten metal solidifies and interlocks at the surfaces of the components after they have been allowed to cool, effectively welding the two components together. As a result of tooling damage, components adhere to one another, and castings have a poor surface finish as a result of tooling damage. This reaction causes the die and its components to become more susceptible to microcracks and pitting, as well as to become thinner and weaker in their walls, necessitating the need for frequent cleaning. A typical aluminum casting die will only last 100,000-150,000 aluminum parts and 200,000-300,000 magnesium parts before requiring significant repairs or replacement. As a result,Instead, a properly maintained steel injection mold can produce a million shots before needing to be repaired or replaced entirely.

When soldering fails, core pins can be damaged, which can result in the need for secondary drilling. This is a classic example of the soldering issue because it can happen to core pins during the casting process. It is common practice to use core pins to create holes in cast parts in order to reduce the amount of secondary drilling that will be required later on. According to Dan Sheridan, toolroom/die repair supervisor at the company's Monticello facility, several large jobs in magnesium were being produced at the Twin City Monticello aluminum die castings. For the project in question, the design and manufacture of a two-piece frame for the center display panel on passenger vehicles was required. The frame's dimensions were approximately 6 by 6 inches (15 by 15 centimeters). On a regular basis, we had to stop the casting process to clean and polish the core pins in order to reduce the possibility of soldering occurring during the casting process. Twin City was producing 240,000 pieces per year, and their four-cavity die required four custom core pins per cavity, resulting in unaffordable downtime and productivity losses.

Sheridan informed us that we had already experimented with a number of high-end coated products that, as she explained, did not last very long after they were applied. Each passing minute brought us closer to a state of irritability. Eventually, after a short period of time, the protective coating would begin to flake away, and the benefits would be permanently lost. It was as a result of this that we were forced to shut down the facility three or four times per shift in order to clean and polish the core pins. The reason for this was that our parts were becoming out of specification and it was taking us an average of 45 minutes to clean and polish them each time we went into them. Furthermore, we had to swap out those pins on a monthly basis, which was extremely inconvenient for everyone who had to participate. This seemingly endless cycle caused the organization to experience significant downtime, scrap parts, and frustration.

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