Die Casting Melt Purification: The Solution to Porosity, Inclusions, and Other Casting Defects at the Source

I. Introduction: The Key to "Cleaner" Castings

In die casting, if impurities like dross or oxides get mixed into the Aluminum melt, the final parts (castings) are prone to problems like Casting porosity, inclusions, and cracks, often leading to scrapped parts. Our Die Casting Melt Purification & Filtration Consumables are the specialized tools for impurity separation and purifying molten aluminum, acting as the first line of defense for casting quality.

DASEON has designed a three-stage purification solution: first, a Filter Box Lining for primary filtration; second, a Filter Grate for fine filtration; and finally, a Slag Ring to block any remaining dross. All three consumables are high-temperature resistant, withstand erosion from molten aluminum, and are non-stick. They are suitable for everything from small-batch production to large-scale Precision die casting, helping factories upgrade from "crude production" to "precision manufacturing."

II. Core Products Explained: Three Consumables to Clean Molten Aluminum Step-by-Step

(A) DR-ACV 2.0 Filter Box Lining — The Strong "Inner Liner" for Your Die Casting Melt Filter Box

1. In a NutshellThis is the "inner liner" of a Die Casting Melt Filter Box. Molten aluminum flows into the box, and this liner supports the ceramic filter plate while preventing the liner itself from shedding particles and contaminating the Aluminum melt. It is the foundational "container" for aluminum melt filtration. Under normal use, it lasts for over a year.

2. Key Features

• Durable Material: Withstands Aluminum melt temperatures of 650-750°C without cracking or deforming.

• Flexible Sizing: Standard sizes range from 12 to 23 inches, fitting most common Die Casting Melt Filter Boxes. Custom sizes are available.

• Non-Stick & Easy to Clean: The smooth surface prevents aluminum from sticking, simplifying maintenance.

3. Who Can Use It?

• Small-Batch Producers: For factories making appliance or electronic parts, it effectively reduces Casting porosity.

• Large-Batch Producers: Ideal for plants manufacturing parts like NEV housings, making it a key component for the purification of large-scale die castings.

• Special Processes: Custom liners are available for applications like aluminum billet production or Precision die casting.

4. How to Use & Maintain

• Before Installing: First, clean the inside of the filter box, removing any old residue or dust. Check the new liner for cracks or chips; fix minor flaws with special mortar, or replace it if there's major damage. Seal the gap between the liner and the box with mortar to prevent leaks.

• During Use: Place the liner in the box, align the openings, and then insert the ceramic filter plate (make sure there are no gaps, or the melt will bypass it). Before the first use, preheat it to 350-400°C for 1-2 hours to dry it out. Keep the melt flow rate under 0.5 m/s to ensure proper filtration.

• Daily Maintenance: After each use, wait for the liner to cool below 200°C (cool enough to touch), then use compressed air to blow out any residue. Don't scrape it with hard tools. Check it every two weeks and apply a non-stick coating if the surface is worn. Replace the liner if it has large cracks, worn-out openings, or stubborn aluminum buildup. It should last over a year with normal use.

(B) DR-ASR 2.0 Filter Grate — The Fine Filtration Guarantee for Precision Die Casting

1. In a Nutshell This is a "small grid plate" placed inside the filter box. After the Aluminum melt passes through the filter plate, it flows through this grate for a second, finer filtration. This makes the molten aluminum even cleaner, which is crucial for Precision die casting and solving micro-Casting porosity.

2. Key Features

• Fine Filtration: Blocks fine impurities over 0.1 mm, increasing Aluminum melt purity to 99.9%.

• Durable & Impact-Resistant: The strong material withstands the impact of molten aluminum and does not deform.

• Highly Compatible: Fits all 12-23 inch DASEON liners and is also compatible with other brands.

3. Who Can Use It?

• Precision Parts Manufacturers: For parts like automotive sensor housings, it provides superior die casting melt purification.

• High-Strength Parts Producers: For parts like automotive chassis, deep impurity separation improves the casting's mechanical properties.

• Aluminum Billet Producers: Ensures a more uniform flow of Aluminum melt for a consistent internal billet structure.

4. How to Use & Maintain (Simple Guide)

• Before Installing: Check the grate for burrs, deformation, or cracks. Sand down any burrs with fine sandpaper; replace it if there are large cracks. Clean the filter box and liner, place the filter plate first, then put the grate on top of it.

• During Use: Make sure the grate's grooves face the direction of the melt flow. Preheat it along with the liner to 350-400°C. Keep the melt flow rate under 0.4 m/s to give the grate enough time to catch impurities.

• Daily Maintenance: After use, let it cool below 150°C and sweep off residue with a soft brush. Don't use metal tools. If aluminum sticks, use a heat gun (under 300°C) to soften it for removal. Check the grooves monthly and replace the grate if they are worn down. It should last for a year with normal use.

(C) Die Casting Gate Slag Ring — The Final Defense for Impurity Separation

1. In a NutshellThis is a "small ring" placed at the mold gate or launder exit. Just before the Aluminum melt enters the mold, this ring blocks any floating dross on the surface. It’s the "final checkpoint" to prevent surface inclusions and reduce Casting porosity.

2. Key Features

• Effective Slag Blocking: The ring's edge is higher than the Aluminum melt surface, effectively stopping floating dross.

• Non-Stick & Easy to Clean: The surface has a non-stick coating for easy maintenance.

• Flexible Sizing: Fits gates from 5 mm to 50 mm, with custom options available.

3. Who Can Use It?

• Mold Parts Producers: For parts like car wheels, it ensures a smoother surface finish.

• Factories Using Small Nozzles: Prevents nozzle clogging and reduces production interruptions.

• Small Shops without Filter Boxes: Acts as a low-cost slag removal solution to reduce defects.

• Multi-Gate Molds: Ensures the Aluminum melt is equally clean at every gate.

4. How to Use & Maintain (Simple Guide)

• Before Installing: Clean the area (gate or launder exit), removing any old residue. Choose a ring that matches the gate size (e.g., a 20mm ring for a 20mm gate) and check for cracks.

• When Installing: Use the "embedded" method for mold gates (set it into a small groove) or the "adhesive" method for launders (use high-temperature glue). Preheat it with the mold to 200-300°C. If it's not pre-coated, apply a non-stick coating yourself. Keep the melt flow rate under 0.8 m/s, or the dross might be forced past the ring.

• Daily Maintenance: After a production run, scrape the dross off the ring once it's cool. Re-apply non-stick coating if needed. Check it every two weeks; replace it if the edge is worn down or cracked. The normal replacement cycle is 3-6 months, but for high-impurity melts (like recycled aluminum), replace it every 1-2 months.

III. Conclusion: The Core Value — Your "Worry-Free Assistant" in Production

DASEON's three die casting filtration consumables form a complete solution for die casting melt purification. The core benefits are:

1. Higher Quality Parts: With an impurity removal rate over 95%, this is an effective Casting porosity solution. It reduces defects like inclusions by over 30%, especially for Precision die casting.

2. Worry-Free Operation: The consumables are durable and easy to maintain, reducing downtime. They are highly adaptable for different factories and alloy casting needs.

3. Cost Savings: By reducing scrap rates and maintenance time, these tools save money and improve part quality, making your products more competitive.