What do you know about aluminum processing？

Aluminum processing is the process of manufacturing aluminum materials into parts or products with specific shapes, sizes and properties through various processes and technical means.

Light weight

• The small density of aluminum makes aluminum parts have the significant characteristics of light weight, which is of great significance in the field of aerospace, automotive and other areas with strict requirements for weight.

Good electrical and thermal conductivity

• Aluminum has excellent electrical and thermal conductivity, so it is widely used in the fields of electronics, appliances and heat exchange.

Corrosion resistance

• Aluminum in the air can quickly form a layer of oxide film, has a certain corrosion resistance, but in some harsh environments still need to be surface treatment to enhance its corrosion resistance.

Good machinability

• Aluminum has good plasticity and ductility, and is easy to be processed by various machining methods and molding processes.

1. cast

The molten aluminum is injected into the mold, and the parts of the desired shape are obtained after cooling and solidification. The casting process is suitable for the production of aluminum parts with complex shapes and large quantities.

• Gravity casting: Relying on gravity to fill the mold with liquid aluminum.
• Pressure casting: By applying pressure to quickly press liquid aluminum into the mold, denser tissue and higher dimensional accuracy can be obtained.

2. Cutting processing

The aluminum parts are cut using machine tools (such as milling machines, lathes) to achieve the desired shape and dimensional accuracy.

• Turning: Used for machining cylindrical surfaces.
• Milling: It can process planes, surfaces, holes, etc.

3. Press

The aluminum sheet is stamped with punches and molds to produce parts of various shapes, such as sheet parts and shells.

4. Forging

By applying pressure, the aluminum billet is deformed in the mold, so as to obtain a part with better mechanical properties.

5. Surface treatment

In order to improve the surface properties and appearance quality of aluminum parts, surface treatment processes are often carried out.

• Anodizing: increases surface hardness and corrosion resistance, and can be tinted.
• Spray paint: Provides protective and aesthetically pleasing coating.

Die casting aluminum is a kind of aluminum parts manufactured by die casting process, the following is its general process flow:

1. Mold design and manufacturing

• Design and manufacture die casting molds according to the shape, size and structure requirements of aluminum parts. The mold is usually composed of a cavity (forming the shape of the aluminum part) and a core (forming the internal holes and structure), and the material is generally made of high-strength die steel, and is heat treated to improve hardness and wear resistance.

2. Prepare raw materials

• The selection of appropriate aluminum alloy ingot as raw materials, the common die-cast aluminum alloy ADC12, A380 and so on. Aluminum ingots need to be inspected to ensure that their composition and quality meet the requirements.

3. Smelting

• Aluminum ingots are melted in a furnace, usually at a temperature between 650 and 750°C. In the smelting process, refining agents need to be added to remove impurities and gases to improve the purity of liquid aluminum.

4. Die casting

• Closing the mold: the dynamic mold and the fixed mold are closed to form a closed cavity.
• Casting: the molten aluminum is injected into the mold cavity through the injection chamber.
• Injection: Through the injection system of the die casting machine, the aluminum liquid is filled into the cavity at high speed and high pressure, and is rapidly solidified under pressure.
• Pressure preservation: During the solidification process of liquid aluminum, a certain pressure is continuously applied to compensate for the shrinkage of liquid aluminum to ensure the dimensional accuracy and internal quality of the parts.
• Mold opening: After the aluminum parts are solidified, open the mold and take out the die casting product.

5. Remove spouts and flash edges

• After the completion of die casting, the aluminum parts will have the water mouth left by the pouring system and the flash produced by the mold parting surface, which need to be removed by cutting, blanking and other ways.

6. Surface treatment

• According to the requirements of the use of parts, surface treatment may be required, such as shot blasting, sandblasting, polishing, anodizing, etc., to improve surface quality and corrosion resistance.

7. Quality inspection

• Carry out dimensional measurement, appearance inspection, internal flaw detection (such as X-ray inspection) of die-cast aluminum parts to ensure that the parts meet the quality standards.

8. Follow-up processing (if necessary)

• Some die-cast aluminum parts may require subsequent mechanical processing, such as drilling, tapping, milling, etc., to meet more accurate assembly requirements.

For example, to produce a die-cast aluminum part of an automobile engine cylinder block, the mold is first manufactured according to the design drawings of the cylinder block, and then the appropriate aluminum alloy is selected for melting and die-casting. After the die casting is completed, the water nozzle and flash edge are removed, the surface shot blasting is carried out to improve the surface roughness, and then the internal defects are detected by X-ray, and finally the follow-up processing such as drilling is carried out according to the needs.

1. Light weight

• With a density of about 2.7g/cm³, aluminum is much lighter than many other metallic materials, such as steel (about 7.85g/cm³). This gives aluminum parts a distinct advantage in applications that require weight reduction, such as aerospace, automotive and transportation, helping to improve energy efficiency and reduce operating costs.
• For example, in automotive manufacturing, the use of aluminum engine components and body structures can significantly reduce the overall weight of the vehicle, thereby improving fuel economy.

2. Good electrical and thermal conductivity

• Aluminum has excellent electrical and thermal conductivity. In the manufacture of electronic devices and heat exchangers, this feature enables aluminum parts to effectively dissipate heat and conduct current, ensuring the normal operation and efficient performance of the equipment.
• For example, components in computer radiators and power transmission equipment often use aluminum for good thermal management and electrical conduction.

3. Corrosion resistance

• Aluminum in the natural environment will form a strong oxide film, this layer of oxide film can effectively protect aluminum from corrosion. This allows aluminum parts to have a long service life in outdoor and harsh environment applications.
• For example, the aluminum trim on the building's facade and the ship's components are able to hold up well in wet and salty environments.

4. Good processability

• Aluminum has good plasticity and ductility, and is easy to be formed and manufactured by various processing processes. It can be cast into complex shapes, and can also be processed by cutting, stamping, forging and other processes to meet different design needs.
• Aluminum parts like some complex shapes, such as automobile wheels and aviation parts, can achieve high precision and high performance through advanced processing technology.

5. High recycling rate

• Aluminum is a highly recyclable material, and the energy required to recover aluminum is a fraction of that required to produce primary aluminum. This not only helps to conserve resources, but also reduces the impact on the environment.
• Many industries are actively promoting the recycling and reuse of aluminum materials to achieve sustainable development goals.

anodizing

• This is a widely used method that forms a thick and hard oxide film on the surface of aluminum parts through an electrolytic process. Oxide film can increase the corrosion resistance, wear resistance and hardness of aluminum parts, and can also be dyed to obtain a variety of colors.

Chemical oxidation

• A thin oxide film is formed by chemical reaction between chemical solution and aluminum surface. This method is low cost, but the performance of the film layer is relatively weak.

Electrophoretic coating

• The aluminum parts are immersed in the electrophoretic paint solution, and the resin particles in the paint solution are deposited on the surface of the aluminum parts under the action of electric field to form a uniform coating. Electrophoretic coating has good corrosion resistance and decorative properties.

Powder spraying

• The powder coating is adsorbed on the surface of aluminum parts by electrostatic action, and then the coating is formed by heating and curing. Powder spraying can provide rich color and good weather resistance.

Fluorocarbon spraying

• A high-performance coating method with excellent weather resistance, corrosion resistance and self-cleaning properties, commonly used in construction aluminum profiles and high-end industrial aluminum parts.

electroplate

• For example, nickel plating, chromium plating, zinc plating, etc., can improve the surface hardness, wear resistance and decoration of aluminum parts. However, the electroplating process has a certain impact on the environment.

polishing

• Including mechanical polishing, chemical polishing and electrolytic polishing, it can remove defects and scratches on the surface of aluminum parts, so that its surface is smooth and bright.

Drawing treatment

• A wire drawing tool is used to form a line texture on the surface of the aluminum piece to increase the decorative effect and texture.

etching

• Chemical etching agents are used to etch specific patterns or words on the surface of aluminum parts.

Aerospace

• Used to manufacture aircraft structural parts, engine parts, etc., to reduce aircraft weight and improve fuel efficiency.

Automobile industry

• Such as body structure, engine cylinder block, wheel hub, etc., help to reduce vehicle fuel consumption and improve performance.

Electronics industry

• Make radiators, shells, circuit boards, etc.

Architectural field

• Window frame, curtain wall, etc.

Rail traffic

• The body and internal parts of the train.

In short, aluminum processing plays an important role in modern manufacturing industry, with the continuous progress of technology, its processing technology and application fields will continue to expand and innovate.

Advanced equipment and technology

• Honscn is equipped with the latest high precision CNC machining equipment, such as advanced milling machines, lathes and drilling presses, to ensure high precision and high quality aluminum parts processing.
• Advanced CAD/CAM software is used for programming and design to realize the processing of aluminum parts with complex shapes and structures to meet the diversified needs of customers.

Rich experience and professional team

• Technicians and engineers with many years of aluminum processing experience, they are familiar with the characteristics of various aluminum alloy materials and processing technology, and can quickly solve the problems in the processing process.
• Professional team can provide customers with one-stop service from design to production, according to customer requirements to provide optimized processing solutions, reduce costs and improve efficiency.

Strict quality control system

• A sound quality management system has been established, from raw material procurement to finished product inspection, each link carries out strict quality testing to ensure that aluminum parts meet industry standards and customer specific requirements.
• It is equipped with advanced testing equipment, such as coordinate measuring instrument, hardness tester, etc., to accurately measure the size, hardness and surface roughness of aluminum parts.

Diverse processing capabilities

• Can carry out a variety of aluminum parts processing technology, including cutting, die casting, stamping, forging, etc., to meet the different types and complexity of aluminum parts processing needs.
• It can process aluminum parts of various shapes and sizes, from small precision parts to large structural parts, with flexible production capacity.

Quality raw material supply

• We have established a long-term and stable cooperative relationship with well-known aluminum suppliers to ensure the reliable quality and stable performance of the raw materials used.
• According to customer requirements to select the appropriate aluminum alloy materials, such as 6061, 7075, etc., to meet the performance requirements of different application scenarios.

Efficient production processes and timely delivery

• Optimize the production process, adopt lean production mode, reduce production cycle, improve production efficiency.
• Deliver customers' orders on time or even ahead of schedule, meet customers' emergency needs, and provide customers with reliable supply chain support.

Good after-sales service

• Provide a full range of after-sales service, timely response to customer feedback and complaints, to solve the problems encountered by customers in the process of using aluminum parts.
• Willing to continuously improve the process and service quality according to customer's comments and suggestions to improve customer satisfaction.

Cost control and competitive pricing

• Through effective cost management and optimization of the production process, we can provide customers with competitive prices under the premise of ensuring quality.
• We can provide customers with customized cost control solutions to help customers reduce production costs and improve the market competitiveness of products.

Get a quote