Manufacturing plants that have die casting equipment need to act quickly to resolve any issue that is causing that equipment to drip molten metal from the nozzle or sprue of the equipment. This article discusses some of the problems that can result when dripping is allowed to go on unabated.
One of the immediate effects of dripping is that the process of die casting will be interrupted as an operator has to stop the equipment to extract the flattened drip which has caused the die to become blocked. Such frequent disruptions can result in fewer castings being completed during a work shift. Solving the problem early can allow work to go on at the expected level of productivity.
Frequent dripping will eventually cause the parting line on the die to develop a gap that can allow molten metal to leak out even after the die has been closed/covered. This line damage will keep getting worse as more molten material escapes. Eventually, employees will be put at risk by all that molten metal that is finding its way onto the shop floor. The damage can also compel you to incur the cost of replacing the die casting equipment before it reaches the end of its expected service life.
Dripping also leads to material waste. This is because the molten metal that keeps landing on the floor gets contaminated by various substances, such as grease and dust. As a result, that metal cannot be available to be used immediately without processing it to extract the impurities in it. Most facilities scrap that dripped metal since they lack the equipment or know-how to purify it.
Damaged Sprue Post
Thick drops of molten material can start finding their way onto the sprue post. This molten metal will eventually crack the sprue post and create an opening through which water can get into the gooseneck and the nozzle. This can increase the pressure inside the equipment and cause spills due to the pot boiling over. Additional losses of material can result from such an eventuality. Personnel would also be in harm's way.
Dripping can be very costly in die casting equipment. It is, therefore, necessary for you to address that problem urgently so that you avoid those costs. Numerous measures, such as keeping a close eye on the gooseneck and nozzle temperature, can put a halt to this problem. Invite die casting experts to identify and fix the cause of dripping in case you have failed to do so internally.