Metal splash occur during die casting includes: insufficient mold clamping force, injection pressure is too high or injection speed is too fast and so on.

Metal splash, or the violent expulsion of molten metal from the die, is a serious safety and quality hazard in die casting. It occurs when high-pressure molten metal escapes through gaps or is ejected from vents. This article explains the common root causes and how systematic control can prevent it.

Metal splash during die casting is not an unavoidable hazard but a symptom of process, tooling, or machine instability. Key causes include improper injection settings, worn dies, poor venting, and inadequate clamping force. Prevention requires a holistic strategy of parameter optimization, disciplined maintenance, and machine reliability.

The reasons for metal sputtering during die casting mainly include the following aspects:

• Process-Related Causes of Metal Splash during die casting
• Die and Machine-Related Causes
• How to Prevent and Control Metal Splash
• Solution of prevent metal splash occur during die casting

Process-Related Causes of Metal Splash during die casting

• Insufficient mold clamping force or too large mold gap
• Injection pressure is too high or injection speed is too fast
• Mold temperature is too low

Insufficient mold clamping force or too large mold gap

If the clamping force between the movable mold and the fixed mold is insufficient, or the mold gap is too large, the molten metal may splash out from the gap of the mold.

This situation usually requires reinstalling the mold, increasing the clamping force, and ensuring the parallelism and sealing of the mold.

Injection pressure is too high or injection speed is too fast

Excessive injection pressure or too fast injection speed will cause the molten metal to enter the mold cavity at high speed, resulting in strong turbulence and airflow, causing the molten metal to splash out.

In this case, metal splashing can be reduced by adjusting the injection pressure and speed.

Mold temperature is too low

Mold temperature that is too low will cause the molten metal to cool too quickly, forming condensation droplets, which may splash onto the mold surface or surrounding areas.

Therefore, keeping the mold temperature within a reasonable range is an important measure to prevent metal sputtering.

Die and Machine-Related Causes

• Improper mold design
• Die wear or aging
• Gas entrainment and turbulence effects
• Improper operation

Improper mold design

Defects in mold design, such as small gate size, improper position, or uneven mold wall thickness, may also cause poor flow of molten metal, thereby causing spattering. Optimizing mold design and ensuring that the gate size and position are reasonable can effectively reduce metal spattering.

Die wear or aging

Dies that have been used for too long or are severely worn may cause the gap to increase, thereby increasing the risk of metal spattering. Regular inspection and replacement of worn dies is necessary.

Gas entrainment and turbulence effects

During the die casting process, molten metal will entrain air or other gases when flowing at high speed. These gases will form turbulence during the flow process and may cause metal liquid to splash. Gas entrainment and turbulence effects can be reduced by optimizing the gating system design and using appropriate gas release agents.

Improper operation

Failure of the operator to properly control the injection time and pressure during the die casting process may also cause metal spattering. Strictly following the operating procedures for die casting and training the operators can reduce the occurrence of such problems.

How to Prevent and Control Metal Splash

A systematic approach targeting root causes is essential for prevention.

• Optimizing Process Parameters
• Implementing Rigorous Die Maintenance
• Ensuring Proper Machine Setup and Calibration

Optimizing Process Parameters

Use a scientific approach to set injection speed profiles. Start with a slow phase to fill the runner, then switch to a fast fill speed, avoiding excessive turbulence. Ensure metal temperature is within the optimal range for the alloy.

Implementing Rigorous Die Maintenance

Establish a regular schedule to inspect and replace worn ejector pins, bushings, and seals. Keep vents clean and clear. Check the die parting line for damage or buildup that prevents proper sealing.

Ensuring Proper Machine Setup and Calibration

Regularly verify and calibrate clamp force, ensuring it is adequate and balanced across all tie bars. Check platen parallelism and the condition of the locking system. Ensure die installation is correct and bolts are torqued to specification.

HAICHEN solution of prevent metal splash occur during die casting

HAICHEN integrates features and provides support to directly address splash risks.

• Eliminate metal splash case
• HAICHEN Precision Engineering for Process Stability Advantage

Eliminate Splash during aluminium auto parts die casting production

For example, one our client who producing aluminum transmission components experienced intermittent and dangerous metal splash, causing safety shutdowns. HAICHEN engineers conducted a full audit. They found two main causes: a slightly misaligned die causing uneven clamping on their old press, and an overly aggressive final injection speed setting. We corrected the die alignment on their HAICHEN machine’s precision platens. Then, using our machine’s multi-stage injection control, we refined the profile to reduce the final speed while maintaining fill time. These actions completely eliminated the splash, restoring safe and continuous production.

HAICHEN Precision Engineering for Process Stability Advantage

HAICHEN machines are built with rigid frames, precision-machined platens, and stable, closed-loop hydraulic systems. This foundation ensures consistent clamping and accurate injection control, removing the machine itself as a variable in splash occurrence. Our technology gives process engineers the precise tools they need to establish and maintain a safe, splash-free window of operation, turning a major hazard into a controlled process.

Haichen die casting machine

Haichen is one Chinese die casting machine manufacturer for more than 10years. At the same time, we produce both high pressure cold chamber die casting machine and hot chamber die casting machine. They have durable and highly precise features.

Haichen also produce die casting machine auxiliary equipment. Such as conveyor, vacuum machine, mold temperature controller, industrial robot, sprayer and so on.

We supply cold chamber and hot chamber die casting machine spare parts.

Welcome contact us.