In die casting production, some clients have reported issues with low yield rates and inefficient production of aluminum-magnesium alloy die castings, which has eroded their competitive edge in the market and led to missed opportunities for business expansion and growth.
Thus, enhancing product yield—such as reducing issues like part sticking to molds, cold shuts, and discoloration—while ensuring quality and boosting production efficiency has become a top priority for enterprises. It is critical to their core competitiveness and essential for scaling up. Through combining theoretical knowledge with on-site practice, we have identified key steps to help achieve a yield rate of over 97% for aluminum die castings.
So, what are these critical steps?
As a domestic supplier of mid-to-high-end die casting release agents, we have conducted tests at multiple client sites. While some achieved excellent results, others struggled with low qualification rates due to complex operating conditions, equipment issues, or improper use of release agents. Through on-site troubleshooting, repeated communication with clients, studying specialized die casting literature, and consulting industry experts, we transformed initial skepticism (e.g., clients doubting our expertise and blaming release agents for all issues) into collaborative problem-solving. We identified root causes, proposed solutions, and resolved problems efficiently—marking a rewarding journey.
Though challenging, we ultimately pinpointed critical factors directly impacting casting quality and production efficiency: the "3+1 Model."
The "3" refers to people, machinery, and materials, while the "1" denotes a holistic mindset. Mastering these not only hones problem-solving skills—setting individuals apart for promotions and growth—but also enhances a company’s management efficiency, enabling it to secure core advantages and more partnerships amid fierce competition.
First, let’s focus on the most critical element of the "3+1 Model": people.
It is essential to cultivate die casting managers and on-site operators with holistic and composite thinking.
In daily production, when issues arise (e.g., part sticking to molds, cold shuts, discoloration), remain calm—every problem has a cause. Systematically identify potential contributing factors and eliminate them one by one. Avoid impulsive, habitual problem-solving. Instead, start by analyzing abnormal phenomena, changes in operating conditions/methods, and past similar incidents. Remember: "All difficulties are paper tigers"—concrete analysis conquers all.
Example: Resolving Part Sticking to Molds
Step 1: Understand Basic Operating Conditions and Problem Manifestations
First, gather comprehensive data:
Aluminum ingot material (e.g., ADC12 vs. ADC6).
Melting and pouring temperatures.
Mold temperature (pre-spray and post-spray).
General process parameters (temperature, speed, time, pressure).
Auxiliary die casting materials (composition, dilution ratio, spray state; distinction between water-based/oil-based plunger lubricants, application guidelines, and suitable scenarios; selection of plunger granules, etc.).
Post-casting cleaning and coating requirements.
Next, describe the issue in detail: Where does sticking occur (deep cavities, near gates, or simple areas)? What is the size of the affected area (consistent or sudden change)? Share photos/videos or inspect on-site. Compare current production with previous runs—note any anomalies in machinery, auxiliary materials, or processes. Trace potential triggers across the workflow: alloy melting/refining → auxiliary material selection → machine setup → process parameters → mold preparation/use. Identify the most and least significant changing factors.
Step 2: Hypothesize Potential Causes of Sticking
Key factors contributing to sticking include:
Alloy properties (e.g., iron content <0.6% increasing adhesion).
Mold issues (excessive temperature, overly deep cavities, improper gate design).
Release agent performance (insufficient spray duration/coverage, inadequate temperature resistance).
Spraying equipment (nozzle blockages, inaccurate spray positioning).
Die casting machine issues (unstable pressure, inconsistent speed).
Compare current production records with historical data to pinpoint the most variable factors. Prioritize adjusting easily modifiable parameters (e.g., release agent dilution ratio, spray time) before addressing machine-related issues.
For more information about How to Immediately Improve the Yield Rate of Aluminum Die Castings to Over 97% or die-casting auxiliary materials, and if you need customized die-casting release agent, please contact 15021483232 (same as Wechat)
