Global Top Metal Casting Companies How to Control Quality

At Dandong Pengxin Machinery, our commitment to quality starts from the initial planning and product development stages.We assist customers in conducting all necessary laboratory tests and inspections to ensure superior outcomes.Additionally, our facilities are ISO 9001 certified, operating under a rigorously validated quality management system that guarantees consistent excellence.

Producing high-quality castings requires strict control across multiple stages, including material selection, process optimization, equipment precision, and quality management. Below are the key steps and best practices for achieving superior casting quality from Dandong Pengxin.

1. Foundry Drawing Control Process

At Dandong Pengxin, we implement a rigorous drawing control process to ensure precision from design to production. Our systematic approach guarantees compliance with specifications and minimizes manufacturing risks.

(1) Drawing Receiving & Initial Review

Receive and verify 2D/3D drawings or models (e.g., STEP, IGES, X_T formats).

Check completeness (dimensions, tolerances, material specs, special requirements).

Document Critical-to-Quality (CTQ) characteristics and customer technical agreements.

(2).Process Feasibility Assessment

Conduct Design for Manufacturability (DFM) analysis with cross-functional teams (tooling, casting engineers, QA).

Identify risks (e.g., uneven wall thickness, shrinkage, demolding challenges).

Validate flow/solidification via simulation software (MAGMA, ProCAST).

(3). Drawing Standardization

Optimize drawings for casting (machining allowances, draft angles, parting line marks).

Define inspection benchmarks (X-ray zones, dimensional check priorities).

Issue internal production drawings with unique revision codes (controlled via PDM system).

(4) Cross-Department Approval & Customer Confirmation

Coordinate sign-offs (QA, production, procurement) for manufacturability.

Submit Engineering Change Requests (ECR) to customers if modifications are needed.

Freeze drawings only after written customer approval.

(5) In-Process Control

First Article Inspection (FAI) against critical dimensions.

Periodic audits and mold wear compensation feedback for drawing updates.

(6) Engineering Change Management (ECM)

All revisions require Engineering Change Notices (ECN) with full traceability.

2. Raw Material Control

(1) Metal Materials

Composition Optimization

Use standardized alloys (e.g., A356 for aluminum, HT250 for cast iron, ZG270-500 for cast steel).

Employ spectrometers to monitor impurities

Melting Process

Use electric/gas furnaces with degassing (rotary degassing, argon refining) to minimize porosity (H₂ ≤ 0.15ml/100g).

(2) Molding Materials

Sand Casting: Silica sand (AFS 50-100) + resin binder (furan, phenolic), moisture ≤ 0.3%.

Investment Casting: Zircon sand or fused silica for smooth surfaces (Ra ≤ 6.3μm).

3. Process Design & Optimization

(1) Mold & Flow Simulation

Mold Design

Draft angles (1°–3°), fillet radii (R ≥ 2mm) to reduce stress concentration.

MAGMASOFT/ProCAST simulation to predict shrinkage, misruns, and porosity.

Gating System

Open gating (aluminum) or pressurized gating (cast iron), pouring speed (4–6 m/s for aluminum).

4. Production Process Control

(1) Parameter Monitoring

Temperature Control

Aluminum pouring temp: 720±10°C, cast iron: 1380–1420°C.

Pressure/Speed

HPDC injection pressure: 30–150 MPa, slow shot speed: 0.2–0.5 m/s.

(2) Environmental Management

Humidity control (≤60% in molding shops to prevent sand moisture absorption).

Dust control (bag filters to maintain emissions <10 mg/m³).

5. Quality Inspection & Post-Processing

(1) Non-Destructive Testing (NDT)

X-ray (DR): Detects internal porosity, shrinkage

Ultrasonic Testing: Identifies cracks in thick sections (sensitivity ≥ Φ2mm defects).

(2) Mechanical Testing

Tensile Test: Cast iron ≥ 250 MPa, elongation ≥ 12%.

Hardness Test: Brinell (HBW) or Leeb hardness (error ±5%).

(3) Post-Processing

Heat Treatment: T6 solution (535°C × 6h) + aging (155°C × 8h) for aluminum.

Surface Treatment: Shot blasting (cast steel), anodizing (aluminum).