Q1: Furnace setup, cleaning procedures and controls or inspection processes for maintaining consistent material composition.
Melting and holding furnaces are kept separate.
Recycled scrap (revert) and primary aluminum ingots are proportioned according to a specific mix ratio, with the batch number recorded for every furnace load.
For refining and degassing, nitrogen or argon gas is injected via a rotary degassing unit; the process is conducted at a temperature of 680–710°C for a duration of 30–50 minutes.
The hydrogen content of the molten aluminum is verified during each shift (e.g., via density equivalent measurement or reduced-pressure solidification testing).
Dross removal and furnace cleaning are performed: dross is thoroughly skimmed after refining, and furnace walls are cleared of any buildup during each shift.
The molten metal in the holding furnace is allowed to settle for at least 15 minutes before being transferred to the die-casting process.
Chemical composition is verified for every furnace load by taking a sample and analyzing it with an optical emission spectrometer (OES) to check for key elements (such as Si, Cu, Fe, and Mg).
The results are compared against the alloy grade specifications; any batch falling outside the tolerance range is prohibited from entering the die-casting process.
A traceability chain is maintained, linking each furnace load to its corresponding spectral analysis report and the resulting casting batches.
In short: Spectral verification for every furnace load + isolation of non-conforming material + full furnace-load traceability.
Q2: Casting and porosity controls, particularly in critical spiral wall/trough areas, including vacuum capability and X-ray inspection.
Kingrun does not currently offer vacuum die casting. X-ray inspection is included as standard in our quality control process.
Mold flow analysis as a prerequisite: During the DFM (Design for Manufacturing) phase, utilize software such as Magma or Flow-3D to simulate the filling process—specifically identifying the end-of-fill points and potential air entrapment zones within the spiral wall sections.
Optimize the placement of gate, vent, and vacuum valves is proactively, rather than attempting remedial measures after trial molding.
Localized squeeze pins or spot cooling: For transition zones between varying wall thicknesses in the spiral sections, incorporate localized squeeze pins or high-pressure spot cooling to mitigate shrinkage porosity. (However vacuum systems address air entrapment, they do not resolve shrinkage porosity.)
X-ray inspection standards: Evaluate porosity levels based on the reference radiographs provided in ASTM E505.
Define specific acceptance criteria for the spiral wall regions (e.g., Level 1–2 for critical sealing surfaces, and Level 3–4 for non-critical areas).
Provide X-ray reports and trend data for mass-production batches.
If the client mandates 100% X-ray inspection, it will have heavy impact on cycle time and costs; if sampling is used, define the sampling frequency and the AQL (Acceptable Quality Level).
Post time: Nov-11-2026
