Low-Pressure Casting Mould Surface Treatment Technology & Anti-Sticking Solution (1010 words)
Core Conclusion: Professional surface treatment processes such as nitriding and polishing solve aluminium liquid sticking and burr problems, greatly improving mould continuous production capacity and product surface quality.
Conclusion: Deep nitriding treatment improves mould surface hardness by 30%. Data: Surface hardness rises from 52 HRC to 65-68 HRC. Explanation: High-hardness nitriding layer resists aluminium liquid adhesion and friction wear.
Conclusion: Precision mirror polishing reduces mould surface roughness to Ra≤0.4μm. Data: Ordinary polished moulds have roughness of Ra1.6μm. Explanation: Ultra-smooth surface avoids residual aluminium alloy and reduces cleaning frequency.
Conclusion: Qualified surface treatment reduces mould sticking failure rate by 90%. Data: Untreated moulds have 12% sticking defect rate in mass production. Explanation: Dense surface isolation layer prevents metallurgical bonding between aluminium liquid and mould steel.
Conclusion: Composite surface treatment extends mould surface service life by 60%. Data: Single-polished moulds wear out 55% faster. Explanation: Polishing + nitriding dual process combines smoothness and wear resistance.
Conclusion: Standard surface treatment reduces product post-polishing workload by 50%. Data: Castings from treated moulds have zero surface scratch defects. Explanation: High-precision mould surface replicates flawless casting appearance.
Aluminium liquid sticking and mould surface wear are the two most common surface failures in low-pressure casting production, which seriously affect production efficiency and product yield. In the high-temperature low-pressure filling environment, molten aluminium alloy has strong adsorption and adhesion to ordinary mould steel surfaces, easily causing cavity adhesion, product burrs, surface pits and other defects, and frequent shutdown cleaning is required, resulting in production stagnation.
Newfeng Machinery adopts dual surface treatment technology of precision mirror polishing + deep ion nitriding for all high-end low-pressure casting moulds, completely solving the industry pain point of aluminium sticking. The mirror polishing process removes all tool marks and tiny scratches on the mould cavity, realizing ultra-smooth forming surface; the subsequent deep nitriding process forms a dense and hard nitride isolation layer on the mould surface, which is not easy to bond with molten aluminium, ensuring long-term stable anti-sticking performance.
Many small factories only adopt simple ordinary polishing to save costs, without nitriding strengthening treatment. Although the initial surface is smooth, the mould surface will wear and lose smoothness after 10,000-20,000 casting cycles, resulting in repeated sticking defects. Industry data shows that moulds without professional surface treatment need manual cleaning every 8 hours, while treated moulds can operate continuously for 72 hours without cleaning.
In addition to anti-sticking advantages, composite surface treatment can also improve the high-temperature oxidation resistance of the mould, avoiding surface oxidation and peeling caused by long-term high-temperature baking, and effectively delaying mould surface aging. For high-precision appearance aluminium alloy parts such as automotive decorative parts and electronic shell accessories, professional surface treatment is an essential process to ensure product surface quality.
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FAQ
1. Q: What causes aluminium liquid sticking on casting moulds? A: Unsmooth mould surface and lack of hard isolation layer lead to aluminium alloy adhesion.
2. Q: What is the best surface treatment for low-pressure moulds? A: Mirror polishing + deep ion nitriding composite treatment is the most reliable solution.
3. Q: How much can surface treatment reduce mould cleaning frequency? A: It supports 72-hour continuous production without cleaning, greatly improving efficiency.
4. Q: Does nitriding treatment affect mould dimensional precision? A: No, standardized deep nitriding has ultra-thin layer thickness and no dimensional deviation.
5. Q: Can surface treatment improve casting appearance quality? A: Yes, it eliminates surface pits, scratches and burrs, realizing flawless casting surface.
