Simulation for HPDC: shrinkage porosity case study

by Marcello Cazzaniga August 28, 2018

Simulation for HPDC: shrinkage porosity case study


In this post we are going to explore a case study dedicated to the improvement of mechanical characteristics, by reducing shrinkage porosity in a component for building sector. This post is part of a series in which we explain the importance of simulation for HPDC (High Pressure Die Casting) through the presentation of real life cases.

by Marcello Cazzaniga August 28, 2018

Simulation for HPDC: scrap reduction case study

by Marcello Cazzaniga July 23, 2018

Simulation for HPDC: scrap reduction case study


In this series of posts, we are going to explain the importance of simulation for HPDC (High Pressure Die Casting) through the presentation of different case studies, in which simulation played a crucial role.

In today’s post, after a short introduction, we are going to analyze a real case from automation sector dealing with blistering and air trapping problems that were solved through the use of simulation software.

by Marcello Cazzaniga July 23, 2018

How to avoid defects in die casting surface treatments: painting and varnish

by Caterina Tosca April 9, 2018

How to avoid defects in die casting surface treatments: painting and varnish


In this post we are going to analyze some surface defects in die casting linked to errors in the painting process of zinc die cast products.

by Caterina Tosca April 9, 2018

Die casting surface treatments: avoiding blisters, pitting and other defects in plating

by Caterina Tosca March 5, 2018

Die casting surface treatments: avoiding blisters, pitting and other defects in plating


In this post we are going to list the most common defects in zinc die casting surface treatments, and how to prevent them. These are the defects we are going to analyze in the post:

  • Blisters
  • Pitting
  • Burnings
  • Nodules
  • Flaking
by Caterina Tosca March 5, 2018

Defects in die casting fixable thanks to the Tool Shop

by Caterina Tosca November 10, 2017

Defects in die casting fixable thanks to the Tool Shop


 In this post we are going to discuss some of the most common defects in die casting linked to mold maintenance, and how they can be fixed by the maintenance department. 

by Caterina Tosca November 10, 2017

Mold maintenance and foundry: how to improve the production process

by Caterina Tosca October 13, 2017

Mold maintenance and foundry: how to improve the production process


In this post we are going to describe in detail the relation between mold maintenance department and foundry: how the inclusion of maintenance department and tooling department in the production area can bring an actual economic advantages and time saving.

by Caterina Tosca October 13, 2017

Weight reduction: lightweight as a benefit of co-design

by Caterina Tosca September 29, 2017

Weight reduction: lightweight as a benefit of co-design

In this post we are going to discuss how it is possible to reduce components weight while maintaining their functionality through the use of co-design.

by Caterina Tosca September 29, 2017

Die casting defects: Internal and Superficial

by Martina Fagnani April 6, 2017

Die casting defects: Internal and Superficial


The main die casting defects which occur during die casting can be divided in categories related to different phases of production process.

These defects occur during different moments:

  • Die casting
  • Pre-Finishing
  • Machining operations
  • Surface finishing

In particular in this article we are going to analyze defects related to the first category: die casting.

Is important to remember that not every defect can be avoided during die casting phase, but is necessary to focus on mould design. This happens because during production phase is possible to act on a limited number of parameters and sometimes to solve a problem the designer can only modify mould design.

by Martina Fagnani April 6, 2017

Die casting simulation for shrinkage porosity prediction

by Stefano Polli December 16, 2016

Die casting simulation for shrinkage porosity prediction

In zinc alloy a faster casting method has been developed, which makes it possible to produce castings with specific features, suitable for the manufacturing of automotive parts, large and small household appliances components and hydrothermal systems.

In die casting processes, the mould filling phase is highly critical because defects such as air entrapment and shrinkage porosity might occur. In the mould, gas is compressed by the melt being poured and discharged outside through the vent. Choosing the proper die casting method is the best way to avoid such defects due to pressure and  air entrapment.

To predict shrinkage porosity and other defects, simulation is increasingly used nowadays, as these software require less development cost and time than experiments. Only some specific simulation programs, however, take into consideration the effect of back pressure in the cavity in die-casting.

In this article we are going to discuss:

- What is shrinkage porosity
- Causes of the defect
- How to avoid it with simulation

by Stefano Polli December 16, 2016

HPDC simulation for die casting process optimization

by Stefano Polli December 12, 2016

HPDC simulation for die casting process optimization


In high pressure die casting industry both suppliers and customers are always looking for the best solutions in terms of part load, costs and times for development and manufacturing processes.

by Stefano Polli December 12, 2016