Measurement and Analysis of Die Casting Defects
压铸正在成为制造汽车组件的越来越普遍的方法。随着这一差异，在铸造制造地点时需要快速测量和定量评估，以确定缺陷及其原因以提高质量和收益率。
除了铸造缺陷的原因和对策外，本节还介绍了使用新的4K数字显微镜进行模具铸造的最新检查示例。
- 增加汽车压铸
- Causes of and Countermeasures for Casting Defects
- Latest Examples of Die-Cast Product Inspection
- 单个显微镜，它改变了压铸生产地点
增加汽车压铸
压铸方法是一种铸造方法，其中将熔融金属（例如铝合金，锌合金，镁合金和铜合金）倒入高压下的精确模具中。该方法用于各种产品，因为它能够提供出色的尺寸准确性，美丽而光滑的铸造表面以及高生产率。
据说，汽车组件占所有生产的压铸产品中的大部分。
特别是，铝合金模具铸件经常用于汽车组件，因为它具有较高的电气/导热性，耐腐蚀性和可工程性以及更轻的重量和更高的强度与锌合金模具铸造相比，从而使用锌合金模具铸造，从而用产物实现产物低成本和高回收效率。
Automotive applications include cylinder blocks, transmission cases, and rocker covers. Conventional die-cast products often contain gas, which makes heat treatment and welding difficult, so it is said that it is difficult to apply such products to automotive undercarriage and body components. In recent years, however, special die-casting methods, such as laminar flow die-casting and high-vacuum die-casting, have led to the application of die-casting in more difficult products. Along with this trend, requirements for the functionality and quality of casting have also increased.
Causes of and Countermeasures for Casting Defects
In die-casting processes for automotive components, caution is required for the temperature of molten metal and molds, the pressure during filling into molds, and casting defects caused by gas and air contained in metals. Casting defects will lead to lower strength and thus greatly affect the safety quality of automobiles.
下表列出了内部或铸造表面上发生的典型缺陷，例如铸造孔及其原因和对策。
| 铸造缺陷 | Cause/state | Countermeasure |
|---|---|---|
| 铸造孔 | A blow hole generated by entry of air or gas in molten metal or a sinkage generated due to a short supply of molten metal | 调节铸造压力，更换排气孔，调整要应用的霉菌释放剂的量，或更改门的位置和大小。 |
| Shrinkage | Depression following slow cooling due to a partially overheated mold | Adjust the mold temperature or redesign the mold. |
| Insufficient filling (poor run of molten metal) | The area near the gate cools down too quickly to fill the entire cavity with molten metal. | 改变霉菌温度，调节熔融金属温度或更改门的位置和大小。 |
| 冷关（焊接标记） | 低霉菌温度和低倒水压力会导致熔融金属凝固，然后完全在一对模具中扩散，在联合点产生标记。 | 提高霉菌温度，熔融金属温度和柱塞速度或更改门的位置和大小。 |
| Crack/distortion | An insufficient draft angle, an uneven shrink, or an improper extrusion (hot cracking during solidification and cold cracking in cooling processes and over time) | 重新设计形状或更改挤出位置。 |
| 破碎的冷硬层 | 袖子中产生的固化层进入腔体，然后包含在压铸中。 | 调节熔融金属温度和柱塞速度。 |
| Flow mark | A low mold temperature or too much mold release agent | Raise the mold temperature and reduce the amount of mold release agent. |
| 划伤 | Die-casting adhered to a mold when being ejected or an improper draft angle | Sufficiently polish the mold surface and provide an appropriate draft angle. |
| Seizure | 部分过热的霉菌会导致熔融金属的粘附。 | 更改模具释放剂的类型或应用方法或重新设计模具。 |
| 水疱 | 表面附近的压缩气体会膨胀，并在表面肿胀。 | Take the same countermeasures as for cast holes and extend the mold cooling time. |
| 变色 | 一个或多个霉菌释放剂成分使模具表面变色。 | 更改代理。 |
| Rough surface | A rough mold surface is transferred directly to the die-cast surface. | Clean and polish the mold. |
| 硬点 | 一个硬的外来粒子进入熔融金属，例如，在以后的过程中打磨工具破裂。 | 过滤熔融金属。 |
In addition to those causes listed above, there are various other causes for casting defects. In die-casting, quality inspection is important to ensure quality. Accurate analysis, measurement, and evaluation are required, for example, for minute holes, cavities, and improper surface roughness because they have an impact on quality.
Latest Examples of Die-Cast Product Inspection
评估和def的要求之一ect analysis of cast holes and cast surfaces is magnified observation using microscopes. However, because die-cast products are three dimensional, such observation involves problems like the time and effort required for focus adjustment, difficulty of observation and analysis, and variations in defect evaluations.
These factors have led to an increase in magnified observation using Digital Microscopes. KEYENCE's VHX Series ultra-high-definition 4K Digital Microscope, which is fully equipped with state-of-the-art technology, makes it possible to clearly capture cast holes and cast surfaces in die-casting to enable quantitative evaluation with extremely high work efficiency.
Zoomed imaging while keeping the target fully in focus even at increased magnification
Conventional microscopes require time and effort to replace lenses, to change the magnification, and adjust the focus according to the size and location of the target for analysis.
The high-resolution lens and motorized revolver of the VHX Series 4K Digital Microscope enable a seamless zoom function that automatically changes the magnification between 20x and 6000x without lens replacement. Through intuitive operation with a mouse or a handheld controller, you can quickly complete a series of tasks all in a single unit. These tasks range from observation using fully focused high-resolution images of the entire target (using depth composition) to quantitative evaluation using automatic area measurement and 3D shape/profile measurement.
Compared to the image captured using a conventional microscope, the VHX Series offers an overwhelmingly clear image, automatic area measurement, and 3D shape/profile measurement
3D shape and profile measurement of a cast hole
The VHX Series 4K Digital Microscope enables the measurement of 3D shapes and profiles (2D cross-sectional shapes) using height information that could not be obtained with conventional microscopes. Even on an uneven die-cast surface, you can recognize cast holes, blow holes, and all other such minute surface shape changes thanks to the 3D display that fully focuses the entire target.
一个微小铸孔的高磁化图像
通常用于铸造孔观察的显微镜存在不足的放大，分辨率和聚焦调整等问题。
With the VHX Series 4K Digital Microscope, even minute cast holes can be captured clearly and at high magnification.
手持式铸造模具的手持式观察
铸造缺陷不仅是由熔融金属的温度和压力引起的，而且通常是由模具状态引起的。特别是，诸如粗糙铸造表面之类的缺陷通常是由模具内部的微小外观缺陷引起的，因此霉菌检查也是必不可少的。
However, because casting molds for automotive components are generally large, they cannot be cut out for observation and analysis using a microscope. In addition, non-destructive inspection using a conventional handheld microscope has the problem of insufficient resolution for minute cracks.
With the VHX Series 4K Digital Microscope, you can perform magnified observation of minute cracks and other such defective areas on molds thanks to 4K images even while using a handheld lens.
3D形状和轮廓测量压铸模裂
VHX系列4K数字显微镜可实现3D形状显示和轮廓测量，从而实现有效和定量检查。
Automatic area measurement and quantitative evaluation of a cast surface
The VHX Series 4K Digital Microscope also serves as a powerful tool for 2D inspection of 3D cast surfaces. The automatic area measurement and counting functions enable quantitative evaluation of defective areas on cast surfaces with simple operation.
您可以使用这些功能来定量评估缺陷，例如粗糙表面。单个VHX单元可以使用单个设备完成观察，测量和报告。
单个显微镜，它改变了压铸生产地点
VHX系列高清4K Digital Microscope can support not only clear magnified observation using high-resolution 4K images, but also automatic measurement and 2D/3D measurement that are not possible with conventional microscopes.
The VHX Series can be used to quickly identify causes of defects and prevent their reoccurrence thanks to its functions that rapidly provide detailed images and numeric data of cast holes, rough cast surfaces, and other defects at die-casting sites. With these functions, a single VHX Series microscope works as an indispensable tool to improve quality and yield rates amid the expanding breadth of applications for die-cast products and their increasing functional requirements.
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