*ShrinkageProvide riser

Reduce section thickness by providing holeProvision of Aluminum rods

Provide Chilling / CoolingWater coolingAir coolingGraphite coating on sand core.

Optimize metal temperature

Optimize die temperature

Pour exact metalProvide radius.Optimize Mg content.Insufficient metal feeding

Sudden variation in section thickness

Heat transfer through sand core

High metal temperature

High die temperature

Low metal volumeSharp cornersLess MagnesiumSolutionsCauses

*UnfillIncrease the size

Increase no. Of vents

Optimize Metal temperature

Optimize Die temp.(More than 250 C at the cavity)Optimize pouring speed

Clean the vents

Pour exact metal

Min 4mm wall thickness is required for GDC Process.

Optimize Silicon ContentInsufficient air vent size

Insufficient no. of vents

Metal temperature low

Die temperature low

Slow pouring

Air vent block

Low metal volume

Less wall thickness

Low Silicon contentSolutionsCauses

*Flow marksSlow pouring

Low metal temperature

Turbulence flow

SolutionsCausesOptimize pouring speed

Increase Metal temperature

*FlashExcess coating

Die mismatchSolutionsCausesRemove coating

Correct the mismatch

*CrackOptimize Die temperature

Min 2Deg/side is required for GDC Process

Optimize Metal temperature

Increase the Silicon content

Optimize Solidification time

Optimize Solidification time

Provide sharp cornersDie temperature high

Draft angle insufficient

Metal temperature high

Low silicon content

Early ejection

Late ejection

Sharp cornersSolutionsCauses

*Blow holesTurbulent flow

Inclusion

Air entrapment

SolutionsCauses

*PorosityGas in metal

Air vent block

More die spray

Low die temperatureSolutionsCausesDo proper degassing.

Clean the Vent pins

Remove the die coat

Increase Metal temperature

*Ejection Pin DepressionHigh metal temperature

More Die spraySolutionsCausesOptimize Metal temperature

Remove the coating

*Cold shutIntermittent Flow

Insufficient metal

Air vent blockSolutionsCauses

Optimize the volume

Clean the vents

*Drag marksCoating wear off.

Metal catch up

Core bendSolutionsCauses

Analyze the reason for Core bend and correct it.

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