Pressure-tight die castings require aligned part design, filling simulation, vacuum control, machining strategy and a measurable leak-test specification.
Gas can be trapped during high-speed filling, while shrinkage forms where heavy sections cannot feed correctly during solidification. Machining may expose subsurface pores, so sealing faces and bores must be considered before the tool is cut.
A robust plan combines prevention and verification instead of relying on a single inspection.
| Stage | Typical control |
|---|---|
| DFM | Uniform walls, ribs, radii and machining-location review |
| Tool design | Gate, runner, overflow, vent and vacuum layout |
| Production | Shot profile, metal temperature, vacuum level and die thermal balance |
| Verification | X-ray sampling, sectioning, air-decay or pressure test |
| Recovery when approved | Vacuum impregnation for micro-porosity |
The drawing or RFQ should identify test medium, pressure, stabilization time, test duration and allowable leak rate. “No leakage” is not a measurable acceptance criterion and can lead to mismatched fixtures and cycle-time assumptions.
No. X-ray reveals internal discontinuities, while a functional leak test verifies the assembled pressure boundary. The methods are complementary.
Yes, when the application and customer specification allow it. It should be agreed before quotation and validated against the operating fluid and temperature.
Review the relevant product and manufacturing capability.
View capability →Compare the adjacent material or application route.
Learn more →Compare A380 and ADC12 aluminum die casting alloys for castability, strength, machining, corrosion resistance and OEM part selection.
Read guide →Select powder coating, conversion coating, painting, plating, polishing or anodizing for aluminum die cast parts by appearance, corrosion and function.
Read guide →Send the drawing, application conditions and annual volume. Engineering will review the material, process and inspection route.
