Raw Materials: High-quality aluminum alloys (such as LM2, LM6, LM9, L25 ets) are used to ensure durability, strength, and corrosion resistance. The alloy chosen depends on the application, whether it’s for automotive, aerospace, or general industrial use.
Purity: The aluminum should have a minimal level of impurities, as contamination can affect casting quality and performance.
Die Casting: A process where molten aluminum is injected into a steel mold under high pressure. It ensures precise dimensional accuracy and smooth surfaces.
Sand Casting: Aluminum is poured into a sand mold. Though it is more flexible, the surface finish may require additional processing, and the molds are single-use.
Tolerance: Aluminum castings should meet strict dimensional tolerances to ensure they fit precisely into their intended application. Tight tolerances reduce the need for additional machining and improve cost-effectiveness.
Surface Finish: The surface finish can range from rough to highly polished, depending on the casting process and customer requirements. Surface roughness and defects like sand inclusions or porosity should be minimized.
X-ray Inspection: This non-destructive test detects internal defects such as porosity or inclusions.
UT (Ultrasonic Testing): Used to detect subsurface cracks and porosity.
Visual Inspection: Basic checks for surface defects, correct dimensional specifications, and completeness of the cast.
Tensile Testing: Ensures that the casting can withstand stress without failure.
Hardness Testing: Determines the hardness of the aluminum, which is crucial for its intended application.
Pressure die casting is a process that forms metal parts by injecting molten non-ferrous metals like aluminum, zinc, or magnesium into a steel mold under high pressure.
The process enables precise, repeatable production of complex shapes with smooth finishes, ideal for mass production. It includes hot and cold chamber methods, depending on the metal used, and is common in automotive, electronics, and appliances.
Gravity die casting is a metal casting process where molten metal is poured into a reusable steel or iron mold under the force of gravity, without external pressure. It is commonly used for non-ferrous metals like aluminum and copper alloys.
The process produces parts with good dimensional accuracy, strength, and surface finish. It is suitable for medium to high volume production and is often used for automotive components, engine parts, and industrial equipment.
Initiate the process with a thorough consultation to understand the client's vision, goals, and requirements. Discuss budgetary constraints, project timeline, and any specific preferences the client may have.
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