How does die casting improve the durability of pistons and end caps?

1. Dense, high-density structure
During the high-pressure die casting process, aluminum alloy is rapidly filled and solidified in the mold, forming a nearly pore-free, dense structure that makes parts less prone to cracking under high loads.
2. Fine and uniform grain structure
Rapid cooling and high-pressure solidification inhibit coarse grain growth, and the fine grains improve the material's yield strength and fatigue life.
3. Multi-stage exhaust system reduces internal porosity
Through annular exhaust channels and a multi-stage exhaust design (first-stage/second-stage/tail-stage exhaust holes), gases generated during solidification can be discharged promptly, significantly improving the piston's mechanical properties and durability.
4. Local post-treatment technology further enhances high-temperature durability
For example, DuraBowl technology performs local TIG welding post-treatment on the combustion chamber edge of high-load pistons, refining the microstructure and increasing thermal-mechanical fatigue life by 4-8 times.

How to prevent porosity and defects in piston and end cap die casting?

Key measures to prevent porosity and defects in piston and end cap die casting:

1. Multi-stage venting and vent optimization
Using a ring-shaped venting network, combined with precise matching of bushings and venting pins, ensures a constant venting gap, avoiding porosity caused by gas stagnation.
2. High-pressure die casting and precise control of die casting machine parameters
Using high-pressure die casting machines such as 1600T and 800T, along with precise temperature and pressure curve control, ensures sufficient fluidity of the molten metal during the filling stage and uniform stress during solidification, significantly reducing the risk of shrinkage cavities and cold cracks.
3. Closed-loop management of mold temperature and cooling system
Real-time monitoring and adjustment of the mold surface temperature using a mold temperature controller maintains a stable temperature gradient, preventing porosity caused by localized overcooling.
4. Full-Process Quality Inspection and Continuous Improvement
Adopting the IATF16949 quality management system, each batch of castings undergoes non-destructive testing such as X-ray and ultrasonic testing. Defects are promptly fed back to process parameters, achieving systematic risk prevention and continuous improvement.