The origin of abnormal structures and layers formed in practical ADC12 alloy die castings 1 to 22kg in weight is studied by measuring molten metal temperatures in a shot sleeve of die casting machines. The molten metal poured into the shot sleeve rapidly cools down to the eutectic temperature and is injected into a die cavity in the solid-liquid mixture state. When the plunger tip runs through the shot sleeve, solidified layers on the inner wall of the sleeve are peeled off and mixed into the flowing liquid. The solid layers are disintegrated and conveyed into the die cavity to form scattered structures in die castings. The primary aluminum phase already crystallized in the shot sleeve grows into coarse dendrites in die castings.