Common Questions & Answers
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How do I fix Die-Cast products?
Die casting is the process by which modern manufacturing produces large quantities of the same shape finished product, from different raw materials, be it metal or plastic's.
With metals, it refers to the process "Casting" where molten liquid metal (or an alloy) is pored into a mold "die", and allowed to solidify in the shape needed. It is also refered to as "Founding".
There are a number of methods of producing die cast products, the most common with molten metals, being sand-casting. Some other methods used are: Plaster casting, Shell molding and Investment casting.
For the purposes of repair with Durafix Easyweld, we are refering to aluminium-, zinc-, magnesium-, nickel- and copper based alloys. The first three are predominately used to fabricate parts for the automotive, small boating and aerospace industry, because of their low weight to strength ratio. Commonly parts such as engine blocks, sumps, and cylinder heads are made in this way.
The quality of the finished product will depend on the purity of the alloy used and the method of casting employed. Generally the faster the casting cools, the more brittle it will be as a finished product. It will also have a high gas porosity.
When trying to repair parts with Durafix Easyweld, the die-cast products will generally take longer to heat to working temperature and they will produce far more "bubbles", this happens as the heat expands the product and the gas escapes from the metal.
These alloys create an oxide layer when exposed to air, so you will need to keep stirring the weld pool of molten Durafix, when repairing die-cast parts. This will remove any of the gas bubbles from the metal and the oxide within the weld pool. Failing to stir the weld pool, will result in a weak and defective repair.
As with any welding, good care should be taken with preparation and patience when working on the part. Durafix can and will produce a very good, durable repair on die-cast products, as long as the weld is done correctly.
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