Die casting mold quality control
Incoming material inspection
Material Chemical Composition and Purity Testing
Spectrometer analysis is used to test the chemical composition of high-pressure die-casting mold steel and key components, ensuring that the alloy element ratios meet standard grade requirements.
Check for issues such as component segregation, excessive impurities, and non-metallic inclusions to prevent early cracking, fatigue failure, or thermal damage due to material instability.
Metallographic Structure and Heat Treatment Condition Verification
Metallographic microscopic analysis is used to test the material’s grain size, microstructure, carbide distribution, and uniformity.
Verify that the heat treatment condition meets requirements, such as quenching depth, tempering structure, and uniform hardness distribution, to avoid chipping, corner collapse, or thermal fatigue cracks caused by poor microstructure.
Dimensional, Tolerance, and Geometric Accuracy Inspection
Vernier calipers, micrometers, height gauges, projectors, and CMMs are used to measure key dimensions to ensure compliance with drawing tolerances.
Check geometric tolerances such as flatness, perpendicularity, coaxiality, and parallelism to ensure parts have a good assembly foundation.
Surface Quality and Defect Inspection
Identify defects such as cracks, folds, inclusions, porosity, and surface decarburization through visual inspection, magnetic particle testing, or penetrant testing.
Inspection Process
Process Classification and Quality Control Point Setting
Quality control points (QC Points) are set at key processes such as roughing, semi-finishing, finishing, EDM, wire cutting, heat treatment, and polishing.
Each control point must be inspected and confirmed before proceeding to the next process.
First Article Inspection
A comprehensive inspection is performed on the first article of each new process or procedure, including dimensions, tolerances, surface quality, and functional structure.
This verifies the rationality of machining paths, tool compensation, and process parameters to prevent systematic errors from causing batch defects.
Process Inspection and Sampling Testing
Regular inspections and random sampling are conducted during batch processing to monitor dimensional drift, tool wear, equipment stability, and process consistency in real time.
Trend monitoring is implemented for critical dimensions to ensure the processing remains under control at all times.
Data-Driven Quality Management and Traceability
All inspection data is recorded in the quality system or process cards, enabling quality traceability at the part, process, and batch levels.
Once an anomaly is detected, the source of the problem can be quickly traced, and corrective and preventive actions (CAPA) can be implemented.
Through full-process inspection, it is ensured that every high-pressure die-casting mold component meets design requirements throughout the manufacturing process, preventing problems from being concentrated in the assembly or trial molding stages.
Assembly Verification
Mold Trial Validation
This stage verifies whether the mold exhibits any abnormalities under actual high-pressure die casting conditions. It is a crucial step in verifying the rationality of the mold design, machining accuracy, and assembly quality, and is also an important basis for assessing the mold’s mass production capability.
During the mold trial validation process, we evaluate the mold’s performance under near-mass production conditions through multi-stage trial molding (T1). We check the comprehensive performance of the filling, venting, cooling, and ejection systems, and observe the flow path, filling stability, and solidification sequence of the molten metal under high pressure and high speed. We analyze defects such as short shots, splashing, eddies, air entrapment, cold shuts, or weld lines.
Simultaneously, we verify the temperature distribution, thermal balance, rigidity, and clamping surface stability of the aluminum high-pressure die casting mold during continuous production to prevent deformation, misalignment, or fatigue damage. We also systematically analyze and optimize the structure and process for problems such as porosity, shrinkage, flash, deformation, sticking, and tearing found during trial molding, ensuring that the mold has high efficiency, high stability, and high yield in actual production.
Die Casting Part Validation
Die casting part validation is a crucial step in comprehensively evaluating mold quality and manufacturing standards. Ultimately, it verifies mold quality from a product perspective, ensuring the casting possesses stable functionality and reliability, reducing subsequent rework for customers, lowering costs, and mitigating the risks of scrap and production interruptions. Raidy Mold, a Chinese manufacturer of high-pressure die casting molds, ensures die castings meet customer drawings, assembly, and functional requirements through multi-dimensional testing.
Dimensional and Geometric Accuracy Verification
Internal Quality and Microstructure Inspection
Evaluating casting density, grain structure, and local defect distribution ensures it meets subsequent processing and performance requirements.
Appearance and Surface Quality Inspection
Functional, Assembly, and Reliability Verification
Equipment Inspection
We use a 3D coordinate measuring machine (CMM), spectrometer, X-ray machine, 2D image measuring instrument, roughness tester, spectrophotometer, and other advanced equipment for comprehensive testing to ensure the accuracy and reliability of every measurement.
ISO Certification
RAIDY has passed multiple international certifications, including ISO9001:2015, ISO14001:2015, ISO13485:2016, and IATF16949. We continuously improve our quality management system, enhance product quality and service levels, optimize cost structure, improve the working environment, and actively fulfill our environmental responsibilities.
