Monitoring Mold Deformations in Aluminum Die-Casting

Inductive eddyNCDT displacement sensors (eddy current) are used to monitor gaps in aluminum die-casting processes. These precision sensors from Micro-Epsilon increase the service life of the tools involved and product quality, while rejects and expenses are reduced. Their robust sensor design also enables gap measurements in harsh ambient conditions.

In the production of aluminum die-cast parts, liquid aluminum is pressed into a mold under high pressure. The two mold halves must be held together with significant force. Despite this high contact force, the tool halves are pressed apart minimally. This process is also called mold breathing. Although minimal openings are normal and intended during this process, a gap causes fraying on the component if it is too large. These splinters need to be reworked to meet the high quality requirements of the final product. If aluminum residues remain on the tool, they also lead to increased wear, which reduces tool life.

Monitoring tool deformation using inductive displacement sensors based on eddy current enables high product quality combined with improved tool life and reduced rework. Usually, three to four eddyNCDT 3005 eddy current systems are used to ensure consistent gap monitoring at several measuring points.

A system consists of a compact and robust controller, which together with the cable and sensor form a unit. The integrated system design increases robustness and resistance to external factors, making the system insensitive to high temperatures, dust, dirt or pressure, and delivers accurate results regardless of the environment. Due to its compact design, the eddyNCDT 3005 can be integrated into an existing machine at any time.

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