Frequent references to die casting lead most to believe that porosity is an inherent part of the process. While it is true that “run of the mill” die casting normally possesses some internal porosity, current modern day equipment, techniques and capabilities can virtually eliminate harmful porosity.
Modern equipment such as a process controller and monitor will measure features of every shot and automatically adjust control mechanisms. Additionally, use of this device provides network type data gathering for management.
Techniques such as vacuum die casting and squeeze die casting eliminate porosity. Vacuum die casting eliminates air and expands tolerance bands, while squeeze die casting overcomes uncontrollable shrinkage porosity in heavy sections. Modern measuring tools allow the application of these techniques since they are ineffective unless closely controlled.
In addition, application of metallurgical analysis and evaluations brought about by testing and feedback greatly upgrade properties and metal integrity.