아연 다이 캐스팅 결함: 아연 다공성, 콜드 셧, 플래시, 뒤틀림 등 강도와 외관에 영향을 미치는 결함입니다. 이를 방지하기 위해 제어된 온도, 압력, 다이 설계 및 QA가 사용됩니다. 크게 각광받는 제조 공정 중 하나는 아연 다이캐스팅입니다. 아연 다이캐스팅은 복잡하고 정확한 금속 부품을 제작할 수 있습니다. 아연은 녹는점이 낮고 내식성 및 강도가 우수하기 때문에 많은 사랑을 받고 있습니다. 아연 다이캐스팅에 의존하는 다른 산업으로는 자동차, 전자제품, 소비재 등이 있습니다.

그러나 다른 제조 공정과 마찬가지로 아연 다이캐스팅에도 결함이 발생할 수 있습니다. 이러한 모든 결함은 품질, 성능 및 미학에 영향을 미칩니다. 따라서 이러한 결함을 조기에 발견하고 해결하는 것이 중요합니다. 이것이 바로 문제 해결과 품질 보증(QA)이 중요한 이유입니다.

이 백서에서는 다음에서 발생할 수 있는 모든 유형의 결함에 대한 유익한 개요를 제공합니다. 아연 다이캐스팅, 문제 해결 및 효과적인 품질 보증을 위한 몇 가지 팁을 제공합니다. 제조업체가 제품의 품질, 낭비 최소화 및 효율성을 향상하는 데 도움을 주기 위해 노력합니다.

아연 다이캐스팅의 일반적인 결함

다음과 같은 이점이 있습니다. 아연 다이캐스팅 제조 산업에서 높은 수준의 치수 안정성, 강도 및 높은 정확도로 복잡한 형상을 만들 수 있는 가능성과 관련이 있습니다. 그러나 다른 주조 공정과 마찬가지로 결함 가능성이 없는 것은 아닙니다. 이러한 결함은 품질을 향상시키고 낭비를 최소화하며 아연 주조 부품의 신뢰할 수 있는 서비스를 제공하기 위해 이해해야 하는 중요한 요소입니다. 가장 빈번하게 발생하는 결함의 원인, 징후 및 해결 방법은 아래에서 자세히 설명합니다.

다공성

아연 다이캐스팅의 가장 일반적인 문제 중 하나는 다공성입니다. 다공성은 주조 재료의 표면이나 내부에 있을 수 있는 작은 구멍, 공동 또는 구멍으로 정의됩니다. 다공성은 부품의 강도를 떨어뜨리고 무게를 지탱하는 강도를 낮추며 유체 관련 구조물에서 유체 누출을 유발할 수 있습니다.

원인:

• 금속을 사출할 때 금형에 갇힌 공기.
• 빠른 냉각 또는 부적절한 가스 환기.
• 주입 시 용융 아연의 난류가 너무 많습니다.
• 합금의 중독 또는 오염.

표지판:

• 표면에 작은 구멍이 있습니다.
• 스트레스가 많고 약한 부분.
• 비대칭 밀도는 엑스레이 또는 초음파를 사용하여 확인할 수 있습니다.

예방 조치:

• 갇힌 공기가 빠져나갈 수 있도록 다이를 환기시킵니다.
• 난기류를 줄이기 위해 분사 속도를 조절합니다.
• 고순도 합금 사용
• 응고: 응고 속도를 늦추기 위해 금형을 예열합니다.

콜드 셧다운

콜드 셧은 용융 아연의 두 흐름이 서로 만나 융합되지 않을 때 형성됩니다. 이로 인해 눈에 보이는 이음새가 남게 되어 미관과 구조적 무결성이 손상됩니다.

원인:

• 금속 온도가 낮아 조기 응고로 이어집니다.
• 느린 사출 속도
• 금형 설계가 잘못되었거나 흐름 또는 통풍 채널이 불량한 경우.
• 움직임을 방해하는 갈고리, 좁은 벽 또는 기타 복잡한 형상.

표지판:

• 흐름선에 선이 형성되거나 균열이 생깁니다.
• 기계적 무결성 저하.
• 장애에 취약한 영역.

예방 조치:

• 용융 금속을 최적의 온도로 유지합니다.
• 좋은 흐름을 얻으려면 주입 속도를 높이세요.
• 데드 존과 날카로운 모서리를 최소화하기 위해 금형 설계를 개선합니다.
• 부품의 벽면이 균일한지 확인합니다.

플래시

플래시는 금형의 절반 사이에서 새어 나와 주조 가장자리를 따라 얇은 돌출부를 형성하는 왼쪽 금속입니다. 대부분 미관상의 문제이지만 부품 조립에 지장을 줄 수 있으며 추가 마감 작업이 필요할 수 있습니다.

원인:

• 마모되거나 잘못 정렬된 다이
• 외과적 과잉 주입 압력.
• 너무 많은 용융 금속
• 느슨한 다이 클램핑

표지판:

• 얇은 가장자리 또는 울퉁불퉁한 이별선.
• 불규칙하거나 거친 표면
• 수작업으로 다듬거나 가공해야 하는 구성 요소.

예방 조치:

• 다이를 자주 점검합니다.
• 금속의 사출 압력과 부피를 최적화합니다.
• 다이 클램핑이 올바른지 확인합니다.

뒤틀림 또는 왜곡

뒤틀림은 냉각 과정에서 발생하는 부품의 변형으로, 정렬 불량이나 치수 오류가 발생합니다. 이 결함은 어셈블리의 공간이 제한된 부품에서 필수적입니다.

원인:

• 두꺼운 부품과 얇은 부품의 냉각 불균형.
• 금형의 비효율적인 설계 또는 열 전도성.
• 주사위에서 잘못 추출되었습니다.
• 관리할 수 없는 내부 스트레스.

표지판:

• 뒤틀리거나 구부러진 부품
• 라인에 맞지 않는 구멍 또는 특성.
• 제대로 맞지 않는 구성 요소.

예방 조치:

• 섹션의 두께가 가능한 한 충분한지 확인하세요.
• 냉각 시스템과 다이 설계를 간소화하세요.
• 적절한 스트레스 감소 조치를 사용하여 배출을 줄여야 합니다.
• 스트레스 완화 부품 캐스팅(필요한 경우).

표면 결함

표면 결함은 불규칙한 질감, 긁힘, 흠집 또는 고르지 않은 마감으로 구성됩니다. 이러한 결함은 특히 장식적인 측면에서 구성 요소의 미적 및 운영 효율성에 영향을 미칠 수 있습니다.

원인:

• 손상되거나 마모된 금형 표면
• 오염된 용융 아연
• 금형의 충분한 이형 또는 윤활 부족.
• 캐스팅 후 프로세스의 잘못된 처리.

표지판:

• 표면이 거칠거나 칙칙한 패치.
• 일관성 없는 마무리
• 코팅 또는 도금의 어려움.

예방 조치:

• Dies are to be polished and maintained regularly.
• Make sure to use clean and good zinc alloys.
• Use adequate mold release agents.
• Handling of the parts during post-processing.

추가 결함

The other defects that can be found in 아연 다이캐스팅 include sinks, underfilling, or post-processing distortion.

• Sinks: Sinks are depressions that are formed in thick parts as a result of uneven cooling and shrinkage.
• Incomplete Filling: This is a condition that is caused by molten metal not filling all parts of the mold, which is caused by improper gating design or low injection pressure.
• Post-Processing Warping: The parts can be warped in the machining process, heat treatment, or the finishing process.

예방 조치:

• Flatten uniformly thick design parts.
• Maximise gating and venting to get full filling.
• Regulate the rate of cooling and subsequent methods of post-processing.

표 1: 아연 다이캐스팅 결함 - 원인, 징후 및 예방 조치

결함	Cause / Parameter	Sign / Measurement	예방 조치
다공성	Trapped air, turbulence, alloy impurities	Pores: 0.1–2 mm; detected by X-ray/ultrasonic	Die venting: Ø0.2–0.5 mm, inject velocity: 0.5–1 m/s, alloy ≥99.9% purity
콜드 셧다운	Low temp (390–400°C), slow injection (≤0.5 m/s)	Visible seam, weak: <80% tensile strength	Molten Zn 420–440°C, injection 0.8–1.2 m/s, uniform walls 1.0–3.0 mm
플래시	Worn/misaligned die, pressure >80 MPa	Ridged edges 0.1–0.5 mm	Die alignment ±0.05 mm, pressure 60–75 MPa
Warping / Distortion	Uneven cooling, thin/thick walls	Misalignment ±0.2 mm, bent ≤1 mm	Wall thickness 1.0–3.0 mm, cooling ΔT ≤10°C, stress relief
표면 결함	Dirty alloy, die wear	Roughness Ra >1.6 µm	Die polish Ra <0.8 µm, clean alloy, mold release
Sinks / Underfilling	Thick section, low pressure	Depressions 0.2–1 mm	Uniform wall 1–3 mm, injection pressure 60–75 MPa
Post-processing Warping	Machining heat ΔT >20°C	Bent ≤1 mm	Controlled machining temp, gradual cooling

아연 다이 캐스팅 문제 해결

A problematic approach to zinc die casting demands the synthesis of careful observation, testing, and process modification to be used as the essential element of effective troubleshooting. Early detection of defects also minimises wastage and provides quality and reliable parts. The techniques listed below give a step-by-step guide on how to detect and fix the usual casting problems.

금형 검사

The quality of die casting is based on the mold. The common causes of defects, which include flash, warping, and dimensional inaccuracies, are caused by worn, cracked, or misaligned dies. Inspect molds regularly for:

• The die surface shows signs of wear or pitting.
• Parting lines Cracks or damage.
• Misalignment of die halves

Cleaning and lubricating are necessary. Unspent debris / insufficient lubricant may lead to rough cast surfaces, adhesions, or scratches. The use of a routine maintenance plan will help ensure that molds are maintained in good condition, as well as prevent their occurrence after a short time.

금속 온도 모니터링

It is important to keep the molten zinc temperature down. Zinc alloys are thermo-sensitive:

• Low temperature: Will lead to incomplete filling, cold shuts, and incomplete fusion.
• High temperature: It enhances oxidation, porosity, and possible surface defects.

Close attention should be paid to temperature by monitoring calibrated thermocouples or pyrometers, and it is usually maintained at a temperature between 390 and 450 o C. Stable flow, minimized defects, and extended lifespan of dies are assured by constant monitoring.

제어 주입의 압력 및 속도.

The flow, filling, and solidification of molten zinc are directly affected by its injection parameters. Poor conditions may lead to turbulence, air capture, or a lack of even cooling. Best practices include:

• Modifying the injection speed to guarantee the smooth passage of metal in every part of the mold.
• The ability to control pressure to fill shapes of complex shapes without flash.
• Application of ramped/staged injection on complex geometries.

The frequent check of the machine settings and recording of the best parameters to be used in various part designs is a way of ensuring consistency and the elimination of the trial and error changes.

환기 개선

One of the major causes of porosity and cold shuts is trapped air and gases. Good venting guarantees the smooth flow of the metal and full filling of the moulds. Techniques include:

• Checking of vents to ensure they are not clogged per run.
• Installing additional vents in regions likely to be trapped, such as dense or complicated features.
• Having optimized vent depth and width to facilitate gas escape and prevent a flash.
• Increased venting enhances part density and minimizes the expensive rework.

냉각 최적화

Lack of homogeneous cooling results in warping, distortion, and internal stresses. Effective cooling requires:

• Equal opportunities of cooling across the die.
• Elimination of abrupt change of thickness in the part design.
• Achieved by controlled ejection following cooling to avoid deformation.

It can be used to optimize the design of dies by simulation before manufacturing by predicting the cooling behavior and saving production time and scrap.

테스트 및 분석

Defects are detected early, and preventive measures are taken to avoid massive failures. Methods include:

• Visual check: To detect flaws on the surface, e.g, flash or roughness.
• X-ray or ultrasonic: This is done to detect internal defects such as porosity or voids.
• Dimensional measurement: Tolerance of parts.

Defect patterns can also be analyzed to give an insight into root causes, which can be used to give specific corrective measures in temperature regulation, mold management, or injection conditions.

설치 프로세스 문서 및 피드백.

Recording of observations, environments, and patterns of defects is essential to continuous improvement. A documentation of injection parameters, mold conditions, and defects is useful in maintaining a log:

• Identify recurring issues
• Normalise optimal production runs.
• Train operators about prevention methods.

Timely feedback between the operators, engineers, and the quality inspectors will make sure that issues are identified in time and sorted out with the least amount of downtime and scrap.

아연 다이캐스팅의 가공 및 조립 결함

Zinc components may still be defective in machining and assembly after die casting. These problems may impact fit, functionality, and quality.

가공 결함

Sharp edges and burrs can be found during the cutting or drilling process and will interfere with the assembly or destroy the surfaces. Dimensional inaccuracies happen when components fail to fit tolerances, which is normally a result of warping or machine error. Scratches or dents are examples of surfaces that may decrease the quality of parts and impact coatings.

조립 결함

Misalignment is typical of the mismatch of parts, resulting in gaps or stress. Damage to the thread will make fasteners difficult to install and make joints weak. Stress cracks can occur when components are clamped together in the wrong manner, particularly in brittle castings.

예방

Check castings before machining to identify warping or defects. Work with sharp objects and keep machines in order. Proper alignment and torque should be used in assembling. Defect reduction is also achieved through the training of operators on how to handle and implement best practices.

품질 보증 팁

Constant quality needs organized processes of quality assurance. Here are some practical tips:

절차 표준화

Record all the stages, starting with metal melting and the ejection of parts. Stock processes minimise the variation and error of humans.

표 2: 문제 해결 및 QA 매개변수

QA Focus	Parameter / Value	Tool / Technique	혜택
Die Temp	150–200°C	Thermocouple	Uniform flow, prevent cold shuts
Molten Zn Temp	420–440°C	Pyrometer	Minimize porosity & surface defects
사출 압력	60–75 MPa	다이캐스팅 기계	Avoid flash, ensure complete filling
Injection Velocity	0.8–1.2 m/s	Machine control	Prevent cold shuts & turbulence
Vent Size	Ø0.2–0.5 mm	Mold-flow check	Reduce porosity, proper gas escape
벽 두께	1–3 mm	CAD / CMM	Minimize sinks, warping
표면 거칠기	Ra <0.8 µm	Profilometer	Smooth finish, easy coating/plating
Cooling ΔT	≤10°C	Temperature sensors	Reduce warping & internal stress
검사	100% visual, X-ray spot check	X-ray, ultrasonic, caliper	Early defect detection, scrap reduction

고품질의 원자재 사용

Lack of zinc alloys can lead to porosity, inclusions, and poor surface finish. Only certified suppliers and materials should be used.

다이 유지 관리

Maintenance prolongs dies and minimizes defects. Inspect wear, cracks, and alignment. It is necessary to polish and lubricate.

프로세스 매개변수 모니터링

Monitor the temperature of the metal, the rate of injection, and the temperature rate. Minor variations could result in major defects. Automated monitoring can be used wherever feasible.

검사에 검사 지점을 설치합니다.

Check components at various levels before completion, post-ejection, and before being shipped. Areas of early detection minimize scrap and rework.

직원 교육

Professional operators are able to detect possible problems fast. Conduct ongoing training on methods of die casting, safety, and quality assurance.

지속적인 개선 문화 수용하기

Get inspection feedback to make processes better. Determine the trends of defects and change molds, materials, or process parameters.

다이캐스팅 결함을 방지하는 방법

Die casting failures may have a major impact on the quality of the parts, efficiency of the production process, and cost. Manufacturers can minimise defects through best practice design, setup, and production through measures like porosity, cold shuts, flash, warping,g, and surface imperfections. These problems are minimized through the following tips that help to be practical.

성공적인 결함 관리

A systematic defect monitoring system is important to ensure that there is constant quality. Quantitative monitoring of defects enables manufacturers to detect trends and areas of problems at an early stage. Statistical Process Control (SPC), automated optical inspection, X-ray,y or ultrasonic testing are techniques that can be used to identify surface and internal defects. A defect rating system in which every problem is measured in terms of severity and frequency is used to prioritize corrective actions. Constant inspection will mean that a small quality problem will not get out of hand, the scrap costs will be minimized, the post-processing recovery will be minimized, and wastes will be reduced.

올바른 벽 두께

The proper wall thickness is very important in ensuring even cooling, structural stability, and avoiding defects. To be more exact, zinc die castings are the best at approximately 1.0 mm thickness, whereas aluminum components are more commonly 1.5 to 2.5 mm thick. Uniformity will minimize chances of shrinkage, warping, sinks, and porosity. Sudden variations in wall thickness or corners may cause stress concentrations and slow the smooth flow of metal, resulting in cold shuts or partial filling. Transition should be done with fillets or radii by designers and should have a gradual change of thickness to enhance the reliability of casting.

예측 가능한 채우기 시간

The controlled fill is used to make sure that the mold is filled effectively without turbulence and pre-solidification. With the calculation of PQ 2 or mold-flow simulation software, engineers will be able to optimize injection speed, pressure, and fill time. Verifiable flow minimizes and removes defects such as cold shuts, partial filtration, or local porosity. By injecting in stages, that is, increasing velocity progressively with the fill cycle, turbulence can be avoided, as well as homogeneous solidification, when using complex geometries or multi-cavity molds.

최적의 금속 흐름 패턴

A correct gating and runner system must be designed in order to ensure a smooth and controlled flow of metal. The correct flow helps to reduce turbulence, the entrapping of air, and the filling of all the mold cavities. Gates are to be fed in the thicker parts first and last in the thinner part and sharp corners or dead ends are to be avoided. Venting systems and overflow wells assist gases in being discharged without creating surface blemishes. A properly designed flow pattern enhances casting density, minimizes internal defects, and, in addition, has dimensional accuracy.

적절한 금형 온도 조정

The right die temperatures are important in ensuring uniform cooling, smooth flow of metals, and dimensions. Prior heating of the die prior to injection helps in avoiding thermal shock and early solidification, whereas even distribution of cooling lines helps in avoiding warping and distortion. Thermocouples or automated sensors used to monitor die temperatures can be used to make real-time adjustments in the production process. Adequate temperature control minimizes cold shuts, surface defects, and internal stresses and maximizes cycle time as well as uniform part quality.

GC 정밀 금형 소개

GC Precision Mould Co., Ltd. is a giant precision manufacturer dealing in custom die casting and high-quality metal parts. The company is based in Dongguan, China, and it has a history of over 20 years of service to the world industries in terms of aluminum, zinc, and magnesium die casting, plastic injection molding, and precision CNC machining. Having such sophisticated production facilities as mold design and prototyping up to surface finishing and assembly, GC Precision Mould provides a full-service with high quality control, supported by ISO and IATF certification, and the desire to make customers satisfied and offer them the best delivery. (aludiecasting.com)

결론

Zinc die casting is an economical production procedure. Nevertheless, the mistakes are typical when the processes are not strictly regulated.
The initial step is the knowledge of typical defects such as porosity, cold shuts, flash, warping, and surface. Then, problems are solved with the help of troubleshooting methods, including venting optimization, temperature control, and mold inspection.
Lastly, vigorous quality control measures such as routine practices, die care, parts inspection, monitoring of processes, and personnel training and development guarantee high-quality parts.

Due to a combination of defect troubleshooting and robust QA, the manufacturers can minimize waste, achieve cost savings, and provide reliable, long lasting of zinc die cast components.
An investment in quality today will guarantee high-quality products tomorrow.

자주 묻는 질문

GC 정밀 금형에서 사용할 수 있는 재료는 무엇인가요?

GC Precision Mould deals with aluminum, zinc, and magnesium die casting. We also have precision plastic injection molding and CNC machining,g which enables us to make high-quality components for a variety of industries.

어떤 산업에 서비스를 제공하나요?

Our customers are in a variety of industries, such as automotive, aerospace, electronics, medical devices, and machinery. The precision molds and complicated parts that we specialize in can satisfy the needs of prototyping and mass production.

GC 정밀 금형에서 맞춤형 설계를 처리할 수 있나요?

Yes, we are provided with complete custom-designed solutions- including design of moulds, prototype, and actual production. Our team works in close coordination with customers to make sure that parts are of the correct specifications and of appropriate quality.

GC 정밀 금형에서 운영하는 품질 기준에는 어떤 것이 있나요?

We uphold our quality in the process of production, and we respond to ISO and IATF standards. Defect-free components are guaranteed by sophisticated inspection procedures such as X-ray and dimensional analysis.

다이 캐스팅 외에 다른 서비스에는 어떤 것이 있나요?

We also offer services of die casting, mold design, CNC machining, surface finishing, assembly, and post-processing. This multifaceted approach will guarantee a final product of high quality that is ready to use.