Porosity is a common concern in aluminum die casting. It may be caused by trapped air, gas inside the molten aluminum or shrinkage during solidification. Depending on its location and severity, porosity can influence strength, machining quality, sealing performance and surface finishing.
High-vacuum die casting removes more air from the mold cavity before and during metal injection. With less trapped gas, the molten aluminum can fill detailed features more effectively and produce a denser casting structure.
Vacuum control is especially valuable for components containing deep ribs, bearing locations, curved air channels and complex mounting structures. These geometries may otherwise create areas where air becomes trapped during filling.
However, vacuum equipment is only one part of porosity control. Mold temperature, injection speed, metal temperature, vent design, overflow placement and cycle consistency must also be managed carefully.
Machining requirements should be considered during casting development. If a bearing bore or sealing surface passes through an area with internal pores, the defect may become visible only after material is removed. For this reason, critical machining zones should be reviewed during mold-flow and process planning.
Trial production, dimensional inspection and internal-defect testing can be used to verify the process before mass production begins.
The company’s production materials describe the use of high-vacuum die casting to reduce porosity and shrinkage-related defects, supported by automated die-casting cells and precision CNC machining equipment.
