In the die-casting industry, part quality and productivity are the cornerstones of competitiveness. For precision castings such as passage comp, which demand exceptional airtightness, sintering-related leakage has long been a primary cause of scrap, plaguing many manufacturers. Often, this issue lies beyond the capabilities of traditional cooling methods. A recent case study from Raidy Mold—on the significant improvement of passage comp sintering leakage scrap rates through Jet Cooling Solution—clearly demonstrates how this innovation efficiently, precisely, and reliably solves challenges that conventional cooling cannot.
The Limitations and Pain Points of Conventional Cooling
Initial analysis by Raidy Mold showed an overall annual scrap rate as high as 8.9% for their passage comp, with more than half (53.3%) of this scrap originating from lamination and leakage defects. Root cause analysis revealed the core issues:
- Ineffective Elimination of Mold Hot Spots: Hot spots existed in the mold design. Although traditional methods attempted to use point cooling pins, they often failed to sufficiently reduce temperatures in these critical areas due to inadequate cooling channel depth or intensity. This led to product surface burning, lack of oxide layer, and ultimately, leakage.
- Uneven and Insufficient Cooling: Mold insert temperatures were too high. Conventional cooling could not provide sufficient and uniform cooling efficiency, causing deep burns in the product, which also led to leakage.
- Mold Structural Deformation Causes Lamination: Wedge blocks for core-pulling mechanisms lacked rigidity, deforming over prolonged production runs. This caused core pulling retraction, abnormal increases in product machining allowances, and resulted in lamination defects.
Conventional cooling methods often lack the precision, efficiency, and consistency needed to address these complex, deep-rooted thermal management problems.
The Precision Solution of Jet Cooling
Raidy Mold‘s Jet Cooling system was specifically designed and applied to effectively address those exact specific and difficult problems that were mentioned earlier:
- Efficient and Precise Hot Spot Control: For mold hot spots, specially manufactured inserts using 3D printing technology replaced standard inserts. 3D printed inserts allow for the creation of extremely complex, conformal cooling channels that follow the product contour, directing coolant directly to the core of the heat source. Coupled with high-pressure, high-efficiency precision cooling control from the Super Point Cooling machine, this system instantly removes large amounts of heat, completely solving burning and leakage caused by insufficient cooling.
- Superior Cooling Uniformity and Reliability: The Jet Cooling system provides stable and controllable high-pressure cooling, ensuring effective and consistent temperature control in critical insert areas. This eliminates local overheating, guarantees the integrity of the product’s dense surface layer, and fundamentally prevents leakage caused by oxidation due to excessive heat.
- Collaborative Design Ensures Structural Stability: Although Jet Cooling directly addresses cooling, the solution is systemic. For example, increasing the thickness of core-pulling wedge blocks (to 25mm) significantly enhanced rigidity, preventing deformation and retraction, thus eliminating the resulting lamination defects. Jet Cooling ensures the mold operates within an optimal temperature range, which indirectly benefits structural stability.
Data-Driven Significant Improvement
The quality improvements and economic benefits delivered by Jet Cooling are quantifiable and significant:
According to the chart shown, In June 2019, the CNC production quantity was 17,190 units, with 1029 units experiencing leakage. The leakage rate was 5.98%. In June 2020, the CNC production quantity was 30,036 units, with 365 units experiencing leakage. The leakage rate was only 1.2%.
A comparative analysis of leakage data from June 2019 and June 2020 demonstrates that the implementation of 3D-printed inserts significantly reduced leakage rates, thereby diminishing the need for impregnation processes and enhancing overall production efficiency. Leakage rate reduced by up to 80%, the defect rate has decreased significantly.
Win-Win in Productivity and Economic Benefits:
The significant reduction in scrap rate directly saves material and processing costs.
Fewer leakage defects mean the need for subsequent impregnation processes is greatly reduced, simplifying the process flow, saving impregnation costs, and improving overall production tempo.
Improved quality stability reduces rework and customer complaint risks.
While the leakage rate plummeted, monthly production volume significantly increased (from approx.17k to 30k pcs), demonstrating the positive impact of technical improvements on production stability and efficiency.
Conclusion
The case eloquently proves that the Jet Cooling system advocated by Raidy Mold is not merely an upgrade in cooling methods but a precision revolution against die-casting thermal management challenges. Through high efficiency heat extraction, precision cooling targeting, and reliable system performance, it effectively solves deep-seated problems unreachable by conventional cooling, such as complex hot spots and local overheating, thus playing a decisive role in achieving quality breakthroughs for high-end die castings.
If you are facing similar quality bottlenecks and seeking effective solutions to improve product yield and reduce production costs, RAIDY MOLD’s Super Point Cooling technology and comprehensive mold solutions could be your ideal choice. Contact us to explore more possibilities in die-casting production.
