Key Parameters that control Quality in HPDC

High-pressure die casting (HPDC) is known for its ability to produce high volumes of metal parts with tight tolerances and smooth surface finishes. But like any precision process, the quality of the final part depends heavily on controlling key process parameters throughout the cycle.

Here are some of the most critical parameters that influence casting quality:

1. Injection Speed and Pressure

Too low, and the metal may not fill thin-walled sections. Too high, and you risk air entrapment or flashing. Optimizing the multi-stage injection curve (slow fill → fast shot → pack) is essential for balanced flow and dimensional stability.

2. Die Temperature

Inconsistent die temperatures can lead to cold shuts, porosity, or incomplete fill. Most tools are preheated to 180–250°C before starting a run and are continuously monitored during operation using thermocouples or IR sensors.

3. Melt Temperature

Typically maintained between 630–700°C for aluminium alloys. Overheating causes oxidation and hydrogen absorption; underheating leads to poor flowability and premature solidification.

4. Cooling Time

Time must be sufficient for solidification, but not excessive to slow cycle time. Improper cooling creates internal stresses or dimensional instability.

5. Ventilation and Overflow Design

Poor venting traps gas, which leads to porosity. Overflow pockets and vacuum assist systems (if used) help evacuate trapped air before metal fills the cavity.

LVIO’s Approach to Process Control

At LVIO Precision, every project undergoes setup validation using mold flow analysis, die temperature mapping, and casting trials to fine-tune injection speed. Our engineers optimize these parameters based on part geometry, alloy, and customer tolerance needs — ensuring reliable quality, shot after shot.