Variation in Die Casting

Basic Aluminum Casting Co.

For over half a century The Basic Aluminum Casting Company has been a privately held, financially solid die casting company with a professional integrity matched by few in today’s industry.diecasting

At The Basic Aluminum Casting Company, we bring quality die casting with delivery and pricing achieved through a sound business organization. Centrally located in Cleveland, Ohio, we’re easily accessible across the Midwest and the entire United States. Occupying over 55,000 square feet at our plant, Basic has serves the transportation and general manufacturing industries and beyond! The Basic Aluminum Casting Company can be best described as an engineering company with one simple trait – creating die cast products  from listening and understanding our customer’s needs.  A strong commitment to that and a focus on quality has enabled us to continue to be one of the best and oldest names in the industry.


The science of statistically analyzing the variation in variations in die casting’s memass production parts has come a long way in the past 50 years.  Statistical analysis has significant uses in die casting, but certain die casting specific variables must be taken into account.

When analyzing variation in mass production components, people often fall back to dimensional variation.  Often times, dimensional variation falls into known, repeatable patterns allowing statistical models to function properly.  Normal bell curve or one sided distributions lend themselves to analysis very well.

Unfortunately, a number of die casting variables and failure modes are not easily measured, such as appearance or porosity.  Porosity found after machining or in X-ray in particular is difficult to model or analyze due to its inherent odd shape.  Many OEM’s have tried to come up with systems for doing this as an inspection criteria with some success.  However, actually utilizing statistical techniques to control porosity is difficult.

With any process control, the inputs into the process are key to maintaining a stable and repeatable output.  Die casting presents a large number of variables in inputs such as:

  • Gate geometry
  • Vent geometry
  • Die temperature and cooling profile
  • Metal temperature and chemistry
  • Injection parameters, such as plunger velocity and pressures
  • Lubrication system and set up

 

It is critical that die casting companies take all of the associated variables into account and control them in order to minimize casting output variation.  Even with such, failures are often due to special causes of variation, such as mechanical breakdown of a system instead of normal wear issues that can be caught beforehand by statistical methods.

By minimizing the variation in process inputs while monitoring process output, Basic Aluminum seeks to apply standard statistical techniques to reduce delivered die casting variation to customers.