Standard LPDC casting mold trial-test is a mandatory pre-delivery verification procedure, adopting quantified acceptance criteria to eliminate structural and defect risks for mass production.
The complete LPDC mold trial-test includes 3 rounds of independent pouring tests, with each round containing 5 continuous casting samples for stability verification.
Qualified trial-test results require 2 consecutive batches of zero-key defects, controlling casting mold porosity shrinkage below 0.8% for all sampled workpieces.
Mold opening timing verification is included in the test, requiring mold opening only when casting solidification ratio reaches 85% to avoid deformation and cracking.
Exhaust system performance is inspected during trial-test, ensuring exhaust groove 0.15–0.3mm depth completely discharges internal cavity gas without flash defects.
Cooling water channel uniformity test verifies 12–20mm spacing temperature balance, controlling overall mold temperature difference within 30℃.
Procast CAE simulation pre-simulation data must match actual trial-test results with error less than 5%, proving simulation accuracy and mold rationality.
H13 hot-work steel mold surface condition is checked after trial runs, with no thermal cracks or oxidation adhesion after 500 continuous test cycles.
Aluminum wheel mold trial-test focuses on rim dimensional consistency, while EV structural part mold emphasizes thin-wall forming integrity and strength stability.
Compared with gravity casting mold trial-test, LPDC procedures add pressure holding stability inspection to verify 0.02–0.05MPa pressure sealing performance.
CPC counter-pressure casting mold trial-test upgrades pressure verification standard, requiring stable operation under 0.1–0.15MPa high counter-pressure environment.
Trial-test data records including defect rate, temperature curve and dimensional deviation form official acceptance reports for mold delivery and factory inspection.
Casting mold trial-test is the most critical quality checkpoint before formal mass production of LPDC casting mold, which can effectively verify the rationality of mold structure, cooling layout and exhaust system design. Different from gravity casting mold’s simple trial pouring, LPDC mold test focuses on pressure holding stability and low-defect forming capability, adapting to its low-pressure filling and sequential solidification process characteristics. Professional Procast CAE simulation provides pre-judgment data for trial-test, and the actual test corrects simulation parameters to ensure long-term production stability. For customized aluminum wheel mold and EV structural part mold, targeted dimensional and structural acceptance items are added according to product characteristics. Standard trial-test can screen out hidden problems such as unreasonable water channel spacing, insufficient exhaust and poor sealing performance, effectively reducing post-delivery mold failure rate and casting mold porosity shrinkage defect rate. H13 hot-work steel’s initial operating state is also verified through continuous trial cycles to ensure that the mold meets the 80,000–120,000 standard cycle life in subsequent formal production. Unified quantified acceptance standards ensure consistent quality of each batch of LPDC molds, providing reliable guarantees for stable mass production of aluminum alloy castings.
FAQs
Q1: How many test rounds are required for standard LPDC mold trial-test? A1: 3 independent pouring rounds, with 5 continuous samples per round.
Q2: What is the qualified porosity rate for LPDC trial castings? A2: Casting mold porosity shrinkage strictly controlled below 0.8%.
Q3: What solidification ratio is required before LPDC mold opening? A3: Mold opening is allowed only when solidification ratio ≥85%.
Q4: What is the error standard between CAE simulation and actual test? A4: Data error controlled within 5% to confirm design rationality.
Q5: Does LPDC trial-test include pressure stability inspection? A5: Yes, verify 0.02–0.05MPa low-pressure sealing performance.
Q6: What surface condition is required after trial cycles? A6: No thermal cracks or adhesion after 500 continuous test cycles.
Q7: What is the core difference between LPDC and gravity trial-test? A7: LPDC adds pressure holding and sealing stability verification items.
