One of the significant ways to gain success in the manufacturing sector is through delivering quality, and the same goes for the die casting industry as well. Quality assurance is one of the most crucial factors that cannot be ignored under any circumstances. There are multiple ways a die-cast can fail, and if you let any of those failures slip through your production unit, then it can be disastrous to your finished products. To eliminate the chances of such failures, the best thing you can do is set up an effective quality control procedure that will test all possible failures that can ruin the quality of the die-cast products.

By carrying out a 100% quality test, you can monitor the overall production process, initiating from the incoming of raw materials to the dispatch of the finished products. Quality is one major thing that will set your business apart from your competitors and help you grab the biggest share of the targeted market.

At Oswal Castings, we make use of the latest technology in our testing procedures. We conduct a number of tests to ensure the quality of our products without risking our production capacity. While analyzing our products, the information derived is critical as it helps in determining whether the product is fit for the market or not. At our manufacturing unit, quality assurance is one such step that can never be omitted from the production cycle.

How to test different types of failures in die casting

  • Inappropriate appearance: The establishment of visual criteria is crucial to test the surface finish of die-cast products. This step of the quality assurance process is performed in the initial stages of product development along with the customer to finalize the mold design. There can be multiple reasons behind the poor appearance of a product, but the obvious one is the ineffective casting process controls.

The best way to test the visual appearance of the product is by comparing the actual casting surface with the visual standards approved by the clients. In order to meet the surface needs of the customers, it’s better to create a written cosmetic standard and make it useful in the production process.

  • Porosity: Porosity has become one of the major causes of a defect in the die-cast products. It happens when air bubbles get caught in the part at the time of its casting. A few tiny holes are unavoidable, but if the number increases or the larger ones appear, then it can worsen the integrity of the final products and make them collapse under pressure.

With the use of destructive testing or X-ray techniques, the quality control experts can test for porosity. By implementing precise casting techniques and good process controls, you can prevent excessive porosity and enhance the quality of die-cast products.

  • Dimensional issues: Dimensional issues can occur owing to the wearing of the die or gaps between die halves. Such issues are hard to detect through human vision, but the same cannot be allowed to become the reason for poor quality products. Therefore, it becomes essential to note the critical dimensions on the part print and review with the die caster to ensure that the products are meeting dimensional accuracy. The quality team must measure the dimensions during the casting process to meet the dimensional tolerances.

If dimensional issues are frequently occurring in your die casting process, then it’s time for you to consider repairing the mold or retooling.

  • Leakage castings: The leakage in castings can appear for a number of reasons, including worn dies and porosity. To test leakage castings, you can make the use of an air decay leak tester. Another effective method to test leakage is by submerging the parts in water for a specified time and pressure, and if bubbles appear, then the product is flawed. To avoid such failures, ensure the quality of the mold design.


  • Omitted Painting or Assembly Steps: By looking at the finished products, it’s easy to identify what step you have missed on the assembly line. Omitting any step in the production cycle becomes the reason for poor quality products. It is always better to state clear processes and make a checklist to ensure no step is missed to avoid such issues. To become a leading die caster, you must have a system that will trace parts during the production cycle and ensure that everything is going as planned.


  • Trimming problems: If excess material is left in your die casting unit, then it can be a problem related to poor design or inefficiently performed trimming process. In case you are also facing trimming problems, then you can move towards the use of in-line gaging or mistake-proofing methods to avoid even the subtle trim problems.

Summing up

Product testing is a non-negotiable step when it comes to testing the quality of the die-cast products. It is critically essential as it helps you to eliminate the risk of delivering flawed products to your customers. Defective or flawed products become the reason for the delay in order completion, excess costs, personal injury, property damage, and tarnish your goodwill.

With precise quality assurance, you can easily identify those areas in your production process that can deteriorate the quality of your products. By knowing the weak points, you can take timely measures to improve the quality of finished products. We at Oswal Castings understand the importance of good quality control and perform all the possible steps to deliver high-quality die-cast products.