Optimum performance of metal in the die casting shop in terms of metal loss, sludge generation, and high quality and consistency in mechanical properties of the die cast components are becoming increasingly important. In this context metal quality both from alloy producers’, die casters’ and end users’ perspectives is critical. The term metal quality can be defined to include 1) chemical composition, 2) inclusions and porosity inside the metal, 3) the surface appearance, and 4) consistency. This definition may apply to ingots as well as die cast parts. When the ingots are remelted and processed in the die casting shop, the effect of ingot surface quality and porosity on performance and properties is usually overshadowed by the quality of the processes in the die casting furnace. The paper discusses how the alloy gradually loses its pre-history. If the metal quality becomes inferior, housekeeping may become notoriously difficult, affecting important performance indicators such as up-time of operation and scrap rate. In partnership with the individual die casters, Hydro Magnesium offers assistance and audits to further improve the die caster’s performance and products.

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