Standardized trial‑test data recording reduces post‑delivery technical disputes by 44 %. Complete datasets cover casting parameters, defect observation, dimensional measurement and mold status for LPDC, gravity and CPC counter‑pressure casting mold.
Pre‑delivery trial‑test shall collect minimum 25 consecutive valid shots for EV structural‑part mold. Only 3‑8 trial pieces cannot expose latent thermal‑fatigue risks which emerge after 1 200‑1 800 cycles of aluminum alloy foundry mass‑production.
Trial‑test records must document actual mold pre‑heat temperature 220‑280 ℃, pouring temperature and cycle‑time. Deviation over ±15 ℃ between trial‑test and target working‑condition lowers trial‑result reference value by 37 % for LPDC casting mold.
For gravity casting mold, recorded items include runner temperature distribution, riser filling status and visual shrinkage observation. 31 % of later‑stage shrinkage‑related casting porosity defect trace back to incomplete trial‑test parameter logging before shipment.
CPC counter‑pressure casting mold trial‑test needs full pressure‑rise curve archive. Simply noting static pressure value loses key dynamic‑pressure information; prediction deviation for thin‑wall component quality may reach 29 % versus real‑world production.
Procast CAE simulation report shall attach to trial‑test document folder. At least 8 sampling‑point comparison between simulated hot‑spot location and real casting‑defect position verifies simulation reliability for EV structural‑part mold development.
Dimensional inspection adopts CMM under 20±2 ℃ environment. Record cavity contour deviation, vent‑slot clearance and core‑cavity fit gap; tolerance drift exceeding ±0.04 mm during trial‑test hints H13 hot work steel insert deformation risk.
Surface condition logging covers flash thickness, sticking‑aluminum position and vent‑slot blocking status. Flash thickness above 0.25 mm during stable trial‑run indicates unreasonable fit‑gap for aluminum wheel LPDC casting mold assembly.
Cooling‑channel pressure‑holding test result should be documented: 0.8 MPa holding for 30 min without leakage. Missing leak‑check record brings hidden water‑leak risk, which may induce water‑steam‑related casting porosity defect at customer site.
Every trial‑test casting piece shall mark casting‑sequence number. Section inspection on No.5, No.15 and No.25 casting samples reveals defect evolution trend under accumulating thermal load for CPC counter‑pressure casting mold.
Trial‑test report shall distinguish between adjustable process‑parameter defects and inherent mold‑structure defects. 23 % overseas disputes arise because process‑caused defects are mis‑judged as mold‑design flaws at aluminum alloy foundry end‑user side.
All trial‑test raw data, photos and section‑sample records shall be archived for at least 24 months. Traceable documents support fast failure analysis when LPDC casting mold generates abnormal quality after cross‑border shipment.
FAQ
Q: How many valid casting runs are required for EV structural‑part mold pre‑delivery trial‑test?
A: At least 25 consecutive valid shots to expose latent long‑term failure risks.
Q: What temperature‑deviation reduces trial‑test data reference value significantly?
A: Mold pre‑heat deviation over ±15 ℃ versus target working‑condition reduces validity by 37 %.
Q: What pressure‑holding specification for cooling‑channel leak‑check in trial‑test phase?
A: 0.8 MPa pressure holding for 30 min with zero leakage as qualified standard.
Q: How many sampling points compare Procast CAE hot‑spot prediction with real casting?
A: Minimum 8 sampling‑points to calibrate simulation‑predicted defect‑position accuracy.
Q: Why mark sequence‑number for every trial‑test casting sample?
A: Section inspection on selected samples reflects defect evolution under accumulating thermal cycles.
Q: What ambient‑temperature requirement for CMM dimensional measurement in trial‑test?
A: Measure under 20±2 ℃ to eliminate thermal‑expansion‑triggered measuring error.
Q: How long should trial‑test raw‑data archive be preserved?
A: Archive all trial‑test records for minimum 24 months for later failure trace‑analysis.
