Complete trial‑test records reduce post‑shipment mold troubleshooting difficulty by 47 %. Temperature data, defect statistics and equipment parameters must be logged for LPDC, gravity and CPC counter‑pressure casting mold verification.
Minimum 25 continuous valid shots shall be recorded for EV structural part mold trial‑test. Data from less than 10 shots cannot reflect long‑term stability; 34 % hidden risks only emerge after 15+ cycles under real thermal load at aluminum alloy foundry.
LPDC casting mold trial‑test log should include mold pre‑heat temperature 220‑280 ℃, pouring temperature and cycle‑time. Deviation of pre‑heat beyond ±25 ℃ changes defect distribution and distorts Procast CAE simulation comparison result.
Gravity casting mold records must contain runner flow status, riser filling condition and visual defect statistics. Each casting piece should mark serial number to track defect evolution trend along cumulative shot quantity for aluminum wheel blanks.
CPC counter‑pressure casting mold needs full pressure‑rise curve recording during trial‑test. Pressure gradient deviation over 0.02 MPa/s changes filling sequence and may generate intermittent casting porosity defect that only occurs under specific pressure settings.
H13 hot work steel insert surface temperature shall be sampled every 5 shots during trial‑test. Recording peak temperature supports later comparison with Procast CAE simulated temperature‑field output for model parameter calibration work.
Defect classification shall distinguish gas porosity, shrinkage porosity, flash and cold shut. Mixing defect categories leads to wrong modification direction; 28 % of repeated rework originate from inaccurate trial‑test defect classification.
Cooling‑water flow rate and outlet temperature for each circuit require itemized logging. Flow fluctuation over ±2 L/min alters heat exchange capacity, creating non‑repeatable defects during gravity casting mold trial‑test batches.
Vent‑slot cleaning condition shall be noted within trial‑test documents. Aluminum residue accumulation after certain shots will gradually increase gas‑trapping tendency for CPC counter‑pressure casting mold thin‑wall cavity sections.
Dimensional measurement of casting sample covers key assembly dimensions, minimum 6 measuring points per sample. Abnormal dimensional drift indicates insert thermal deformation risk before formal mass‑production of EV structural‑part mold.
Disassemble mold after completing trial‑test series; record insert surface condition, scratch and micro‑crack observation. Minor surface damage may expand rapidly once mold enters high‑frequency LPDC casting mold workshop production.
All trial‑test reports attach photos of typical defective castings. Text‑only description loses intuitive reference value and raises communication barrier during cross‑border aluminum alloy foundry technical after‑sales support.
FAQ
Q: How many continuous valid shots are required for EV structural‑part mold trial‑test?
A: At least 25 shots; partial latent risks appear only after 15+ casting cycles.
Q: What pre‑heat temperature range should LPDC casting mold trial‑test maintain?
A: Keep 220‑280 ℃; large deviation distorts simulation comparison analysis.
Q: What key curve must be logged in CPC counter‑pressure casting mold trial‑test?
A: Record complete pressure‑rise curve for filling‑sequence evaluation.
Q: Why classify gas porosity and shrinkage porosity separately in records?
A: Mixed classification causes 28 % wrong mold‑modification decisions in practice.
Q: How many dimensional measuring points for each trial‑test casting sample?
A: Minimum 6 assembly‑relevant measuring points for dimension‑trend tracking.
Q: What observation work after finishing mold trial‑test shots?
A: Disassemble and inspect inserts for scratches and early micro‑crack signs.
Q: Why attach defect photos within trial‑test report documents?
A: Reduces cross‑border technical communication barriers for aluminum alloy foundry users.
