Crack in gigacast panel from factory

[Moter3d]

What is a GigaCast?

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[Cold.Truth]

What is a GigaCast?

https://www.usnews.com/news/technol...a-reinvents-carmaking-with-quiet-breakthrough

 

[Jhodgesatmb]

There is a big difference between defects and engineered openings. Also, that is a crack right next to a stress riser so it is very likely to propagate.

But it isn't a crack. That is the point. It is not a design opening either. It is a manufacturing defect. The question is, is it within engineering tolerances? If so, then it looks scary for any of us but might never be a functional issue. A crack would be stress induced and would surely be a problem.

 

[CyberMaxi]

That is a bit concerning did they at least give you a loaner?

Yes a loaner was given. It got a flat tire last week and had to be towed and they told us we would charged for the flat.

 

[CyberMaxi]

But it isn't a crack. That is the point. It is not a design opening either. It is a manufacturing defect. The question is, is it within engineering tolerances? If so, then it looks scary for any of us but might never be a functional issue. A crack would be stress induced and would surely be a problem.

If you look closely at the photo you can see a very fine line or what i would call a hairline crack propagating from the opening. With repeating stress, I don't see how this crack wouldn't propagate eventually. It's much different that any other engineered opening, because stresses are concentrated at the tip of the crack.

 

[Mini2nut]

Replacing the Giga casting would involve quite a bit of labor. I believe it’s attached to the BIW with fasteners and adhesive.

 

[Petertsai]

Why do yall think that a hole is going to significantly impact the casting's safety and/or performance?
Look at the many other steel pieces on the truck, and most all of them have holes in them to reduce the weight and amount of material needed.

I believe the whole casting is defective. Missing metal means that there is probably porousity in rest of casting, I would demand a replacement.

 

[Woodrick]

I believe the whole casting is defective. Missing metal means that there is probably porousity in rest of casting, I would demand a replacement.

Why would you jump to that conclusion?

Have you ever done any casting? It's really hard not to have any air bubbles in one. It's a discipline in itself to get castings right.

 

[Petertsai]

Why would you jump to that conclusion?

Have you ever done any casting? It's really hard not to have any air bubbles in one. It's a discipline in itself to get castings right.

It is injection molded and not casted. Injection molding is done under high pressure. Giga casting is really injection molding at giga pressures, high pressure needed due to the size of the structure.

 

[mongo]

Why would you jump to that conclusion?

Have you ever done any casting? It's really hard not to have any air bubbles in one. It's a discipline in itself to get castings right.

It doesn't seem like air entrapment should be the cause versus a flow issue since they pull a 50 millibar vacuum before injection.
https://www.sunrise-metal.com/tesla-giga-press-die-casting-machine/

One article on castings calls out 4% perosity at atmospheric pressure and 1% at 300 millibar. Extrapolating, 50 millibar would get it even lower, like 0.2%.
https://www.sciencedirect.com/science/article/pii/S0042207X23000568

 

[Woodrick]

It is injection molded and not casted. Injection molding is done under high pressure. Giga casting is really injection molding at giga pressures, high pressure needed due to the size of the structure.

That doesn't quite agree with this explanation
Die Casting vs Injection Molding: Which is the Right Choice? (diecastor.com)
or
Die Casting vs Injection Molding: A Detailed Comparison - rapiddirect

Both of these site indicate that the difference is the material. Injection molding uses plastic, casting uses a metal.

And I thought that Tesla called then "castings"

 

[oisiaa]

I'm not an engineer, but seems like TIG welding would be the best course of action to fill the hole.

 

[Woodrick]

It doesn't seem like air entrapment should be the cause versus a flow issue since they pull a 50 millibar vacuum before injection.
https://www.sunrise-metal.com/tesla-giga-press-die-casting-machine/

One article on castings calls out 4% perosity at atmospheric pressure and 1% at 300 millibar. Extrapolating, 50 millibar would get it even lower, like 0.2%.
https://www.sciencedirect.com/science/article/pii/S0042207X23000568

So, what did cause it? Maybe it was a piece of plastic that caught in the mold. Whatever it was, it's there.

 

[Petertsai]

That doesn't quite agree with this explanation
Die Casting vs Injection Molding: Which is the Right Choice? (diecastor.com)
or
Die Casting vs Injection Molding: A Detailed Comparison - rapiddirect

Both of these site indicate that the difference is the material. Injection molding uses plastic, casting uses a metal.

And I thought that Tesla called then "castings"

I may have used the wrong term. Die Casting is the proper term for injection molding at high pressure of aluminum or zinc. Cast iron is liquid iron poured into a mold and not injected at high pressure. Your links explain that well. I have worked on products where liquid aluminum was injected into a cavity which had a mesh of ceramic wool for better strength.

 

[SighberBeast]

I have the same issue with my Cybertruck in the exact same place (in the driver side wheel well). Currently at Tesla’s service center and they claim they need to wait for their FIELD TECHNICAL SUPERVISOR to respond to my inquiry because he’s unfamiliar with this issue and the first time he’s seen it. Tesla stated they cannot allow me to take the car for safety and liability reasons until his FTS responds. They at least gave me a loaner but concerned how long this will take. This along with two other critical bulletins with one related to the fly by wire.

Does this gigacast issue fall under CA lemon law?

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