Introduce
Aluminum castings are components made from aluminum or aluminum alloys through processes such as smelting and casting. They possess the characteristics of light weight and high specific strength. With a density of approximately 2.7g/cm³, their strength can meet various structural requirements after appropriate treatment. A dense oxide film is easily formed on their surface, endowing them with excellent corrosion resistance, making them suitable for outdoor environments. In addition, they have good thermal and electrical conductivity, and are widely used in the manufacture of radiators, electrical components, etc. Thanks to their good machinability, complex shapes can be achieved through processes such as turning and milling. From automotive engine blocks to aerospace structural components and electronic product casings, aluminum castings play a crucial role in multiple fields and are recyclable, conforming to the environmental protection trend.
Product Description
| Product Name |
custom aluminum casting service |
| Material |
Magnesium, Aluminum and Zinc Alloy |
| Surface treatment |
Customers' Demand |
| Process |
Casting +Machining(if Need)+surface Treatment |
| Service |
OEM\ODM |
| Size |
Customized Size |
| Certification |
ISO 9001:2015 |
| Color |
Customized Color |
| Quality Control |
Own testing center |
| Package |
Bubble + Carton + Wooden Case |
| Tolerance |
Customer's Drawing Request |
| Mould Lead Time |
45days |
Lightweight: The density of aluminum is approximately 2.7 g/cm³, much lower than that of many common metals, such as iron (with a density of approximately 7.86 g/cm³) and copper (with a density of approximately 8.96 g/cm³). Therefore, aluminum castings are lightweight, which gives them obvious advantages in applications where weight is a concern, such as in the aerospace and automotive manufacturing industries.
High specific strength: Although the strength of aluminum is relatively lower than that of some high-strength steels, aluminum castings can achieve a high strength-to-weight ratio through reasonable alloy design and processing techniques. This means that under the same strength requirements, aluminum castings can be lighter than other metal castings, thus improving the performance and efficiency of equipment.
Applications
1.Automotive industry
Engine components: such as cylinder blocks, cylinder heads, oil sumps, etc. The lightweight characteristics of aluminum castings help reduce the overall weight of the engine, improve fuel economy, and their good thermal conductivity is beneficial to the heat dissipation of the engine, ensuring that the engine operates efficiently.
Body structural parts: including doors, engine hoods, trunk lids, etc. The use of aluminum castings can effectively reduce the weight of the body, improve the handling performance and acceleration performance of the vehicle, and can absorb more energy during a collision, improving the safety performance of the vehicle.
2.Aerospace field
Aircraft structural parts: such as wing spars, fuselage frames, etc. Due to their high strength-to-weight ratio, aluminum castings can minimize the weight of the aircraft while ensuring structural strength, increasing the range and payload. Engine components: such as compressor blades, turbine disks, etc. Aluminum castings can maintain good mechanical properties in high-temperature environments, helping to improve the efficiency and reliability of the engine.
3.Electronics and electrical industry
Electronic product casings: such as computer cases, mobile phone casings, etc. Aluminum castings have good electromagnetic shielding performance, which can effectively prevent electromagnetic interference inside electronic devices. At the same time, their lightweight and aesthetic properties meet the design requirements of modern electronic products.
Electrical equipment components: such as transformer casings, switch casings, etc. The corrosion resistance, good electrical conductivity and thermal conductivity of aluminum castings enable them to play an important role in electrical equipment, ensuring the safe and reliable operation of the equipment.
4.Mechanical manufacturing field
Industrial robot components: such as arms, joints, etc. The lightweight of aluminum castings can reduce the inertia of the moving parts of the robot, improve the movement speed and accuracy of the robot, and their high strength can withstand various forces and torques during the operation of the robot.
Machine tool components: such as worktables, machine tool beds, etc. The high rigidity and stability of aluminum castings help improve the machining accuracy and surface quality of machine tools, and their good damping performance can reduce the vibration of machine tools during operation.
5.Building decoration industry
Door and window frames: Aluminum castings have the advantages of beauty, corrosion resistance, and good sealing performance, which can provide good lighting and ventilation conditions for buildings, and at the same time improve the overall aesthetic degree of the building.
Decorative components: such as curtain walls, decorative lines, etc. Aluminum castings can obtain different colors and textures through various surface treatment processes, such as anodizing, spraying, etc., to meet the decorative needs of different architectural styles.
6.Daily necessities field
Furniture accessories: such as table and chair legs, cabinet door handles, etc. The corrosion resistance and aesthetic properties of aluminum castings enable them to play a dual role of decoration and practicality in furniture, and their lightweight makes the handling and use of furniture more convenient.
Kitchen utensils: such as pots and tableware, etc. Aluminum castings have good thermal conductivity, which can transfer heat quickly and evenly, making cooking more efficient. At the same time, their smooth surface is easy to clean.
Production process
1.Mold Design and Manufacturing
Product Design: According to the customer's requirements and the product's usage requirements, use computer-aided design (CAD) software to carry out three-dimensional model design to determine the shape, size, and precision requirements of the product.
Mold Design: Based on the three-dimensional model of the product, design a mold suitable for the casting process. Mold design needs to consider factors such as the parting surface of the casting, the gating and riser system, and the demoulding method to ensure that the molten metal can be smoothly filled during the casting process and ensure the quality of the casting.
Mold Manufacturing: According to the mold design drawings, use machining, electrical discharge machining and other processes to manufacture the mold. The manufacturing accuracy and quality of the mold directly affect the dimensional accuracy and surface quality of the casting.
2.Raw Material Preparation
Selection of Aluminum Ingot: Select the aluminum ingot of the appropriate aluminum alloy grade according to the performance requirements of the casting. Common aluminum alloys include 6061, 7075, A356, etc., and different aluminum alloys have different mechanical properties, corrosion resistance and machining properties.
Preparation of Auxiliary Materials: In addition to aluminum ingots, some auxiliary materials need to be prepared, such as refining agents, modifiers, covering agents, etc. The refining agent is used to remove impurities and gases in the aluminum liquid and improve the purity of the aluminum liquid; the modifier is used to improve the structure and performance of the aluminum alloy; the covering agent is used to prevent the aluminum liquid from oxidizing during the smelting process.
3.Smelting
Charging: Load the selected aluminum ingots and auxiliary materials into the furnace according to a certain proportion. The furnace usually uses resistance furnace, gas furnace or fuel furnace, etc., and select the appropriate furnace type according to the production scale and energy supply situation.
Melting: Heat the furnace to gradually melt the aluminum ingots. During the melting process, the aluminum liquid needs to be continuously stirred to promote the uniform melting of the aluminum ingots and heat transfer. At the same time, according to the need, add refining agents, modifiers and other auxiliary materials to refine and modify the aluminum liquid.
Refining and Degassing: After the aluminum liquid reaches a certain temperature, add a refining agent for refining treatment. The chemical components in the refining agent will react with the impurities and gases in the aluminum liquid to form slag and gas for discharge, thus improving the purity of the aluminum liquid. After refining, methods such as blowing and stirring or vacuum treatment can be used to further remove the gases in the aluminum liquid.
Temperature Control: Precisely control the temperature of the aluminum liquid. Different aluminum alloy grades have different optimal smelting temperature ranges. Generally, the smelting temperature of aluminum alloys is about 700 - 750ºC. Excessive temperature will lead to an increase in the gas absorption of the aluminum alloy and intensify oxidation, affecting the quality of the casting; too low temperature will make the fluidity of the aluminum liquid poor, which is not conducive to filling.
4.Casting
Mold Preparation: Clean and preheat the manufactured mold, and spray a release agent. Preheating the mold can improve the filling ability of the aluminum liquid and reduce casting defects such as cold shuts and misruns. The release agent can make the casting easier to be taken out of the mold during demoulding and protect the surface of the mold at the same time.
Pouring: Pour the smelted aluminum liquid into the mold through a pouring ladle. During the pouring process, control the pouring speed and pouring temperature to ensure that the aluminum liquid can smoothly and quickly fill the mold cavity. If the pouring speed is too fast, splashing and porosity are likely to occur; if the pouring speed is too slow, casting defects such as cold shuts may occur.
Solidification and Molding: The aluminum liquid gradually cools and solidifies in the mold to form the shape of the casting. During the solidification process, pay attention to controlling the cooling rate to obtain good casting structure and performance. For some complex castings, special cooling processes such as local cooling and sequential solidification may be required to reduce casting defects such as shrinkage cavities and porosity.
5.Demoulding and Cleaning
Demoulding: After the casting cools to a certain temperature, open the mold and take out the casting from the mold. Pay attention to avoid damaging the surface and edges of the casting during demoulding.
Cleaning: Remove excess parts such as flash, burrs, and gating and riser systems on the surface of the casting. Methods such as manual grinding, mechanical cutting, and chemical corrosion can be used for cleaning. The surface of the cleaned casting should be smooth and flat, meeting the quality requirements of the product.
6.Heat Treatment
Solution Treatment: Heat the casting to a certain temperature and keep it warm for a period of time to fully dissolve the alloy elements in the aluminum alloy into the aluminum matrix to form a uniform solid solution. Solution treatment can improve the strength and hardness of the casting.
Aging Treatment: The casting after solution treatment is aged at room temperature or a higher temperature. Aging treatment can make the alloy elements in the solid solution precipitate to form fine strengthening phases, further improving the mechanical properties of the casting. According to the aging temperature and time, aging treatment can be divided into natural aging and artificial aging.
7.Surface Treatment
Anodizing: Use the casting as the anode and place it in a specific electrolyte solution for electrolytic treatment to form an oxide film on the surface of the casting. The anodized film has good corrosion resistance, wear resistance and decorative properties, and can improve the service life and appearance quality of the casting.
Spraying: Spray various coatings such as paint and powder coatings on the surface of the casting according to the need. Spraying can protect the surface of the casting, prevent corrosion and beautify the appearance.
Electroplating: Plate a layer of metal such as zinc, nickel, chromium, etc. on the surface of the casting. Electroplating can improve the corrosion resistance, wear resistance and electrical conductivity of the casting, and also improve the appearance of the casting.
8.Quality Inspection
Appearance Inspection: Check the surface quality of the casting, including the presence of defects such as porosity, sand holes, cracks, flash, and burrs, as well as whether the dimensional accuracy and shape deviation of the casting meet the requirements of the product drawing.
Mechanical Property Testing: Use methods such as tensile test, hardness test, and impact test to detect the mechanical properties of the casting, such as tensile strength, yield strength, elongation, hardness, etc., to ensure that the mechanical properties of the casting meet the use requirements.
Metallographic Structure Analysis: Observe the metallographic structure of the casting through a metallographic microscope, and analyze its grain size, phase composition, and structural uniformity, etc., to judge the quality and performance of the casting. Metallographic structure analysis can help to find problems existing in the smelting, casting and heat treatment processes of the casting.
Nondestructive Testing: Use nondestructive testing methods such as ultrasonic testing, radiographic testing, and magnetic particle testing to detect whether there are defects such as porosity, shrinkage cavities, and cracks inside the casting. Nondestructive testing can evaluate the internal quality of the casting without damaging it.
9.Packaging and Transportation
Packaging: After the casting passes the quality inspection, package it according to the customer's requirements. The packaging methods usually include plastic bags, cartons, wooden boxes, etc. to protect the casting from damage during transportation and storage.
Transportation: Select an appropriate transportation method to transport the casting to the customer's designated location. During the transportation process, pay attention to prevent the casting from being collided, squeezed, and exposed to rain, etc., to ensure that the quality of the casting is not affected.
Company Profile
Shandong Meide Import and Export Co., LTD was established in 1997. Located in Liaocheng City, Shandong Province, the largest steel logistics center in North China.We are a Chinese company with over 25 years of forging experience.Our focus is on using high-efficiency electro-hydraulic hammer facilities to produce free forged and open-die forged products.We are proud of our independent quality assurance laboratory, which ensures that all of our products meet our customers' requirements. We have passed ISO9001:2000 quality system certification, SGS, ROSH, TUV and REACH certification. Has cold rolling, hot rolling and other production lines. Such as heat treatment chemical analysis, metal halide testing, physical testing, nondestructive testing and other testing equipment and testing technology, imported physical and chemical testing equipment full spectrum direct reading spectrometer, can quickly and accurately chemical analysis of all kinds of metal materials. According to American ASTM standard, Japanese JIS standard, German DIN standard, British BS standard and other standards production. At the same time, we can customize and develop new products according to the actual application of customers, and provide products for different cost and performance requirements. The company cooperates with more than 20 well-known steel mills in China, and has established modern large outdoor warehouse and indoor warehouse, with 20,000 tons of goods in stock. The customer base covers all provinces and cities in China, and has more than 100 long-term stable cooperative customers. We warmly welcome and look forward tocooperating with you!
Certifications
Packaging & Shipping
Packaging.
Waterproof paper steel ring standard airworthiness export packaging; Packing seaworthy wooden case packing.
Make sure all the goods are delivered to you. If you have any requirements, you can also contact us.
Transportation.
We ship goods from Qingdao, Tianjin ports. You can designate other ports as required.
Our delivery time is within 7-15 days. If the quantity is very large or special circumstances occur, it may be longer,
FAQ
1.Is it possible to know how is myproduct going on without visiting your company?We will offer a detailed products schedule and send weekly reports with digital pictures and videos which show the machining progress.
2.How about your delivery time?
General speaking, if the goods is in stock, we can delivery them with 2-5 days, If the quantity is 1-2 container, we can give you with 18-25days,if the quantity is more than 2 container and you are very urgent, we can let factory priority produce your goods.
3.Will my design drawings be safe when you get it ?
Yes, we will not publish your design to a third party unless your permission is obtained. We can sign NDA before you send the drawings.
4.How to avoid mass order quality problems?
Strengthen the prevention and inspection in advance of the process of production and processing, set important processes as the key point of quality control, follow up the inspection and defense throughout the process.
5.What is your sample policy?
We can supply the sample if we have ready parts in stock, but the customers have to pay the sample cost and the courier cost.
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