Raw Materials Preparation
- Material Inspection: Inspection is carried out in raw aluminium alloy to test purity, chemicals content, and physical factors before production is carried out. This is to validate final casts have undergone tough standards needed in making cars.
Die Casting Process
- Die Production and Design: Dies are manufactured in accordance with detailed sizes and shape of motor car components. Tool steels of better qualities are used to prepare dies that can withstand the die-casting process of high temperatures and pressures. Dies incorporate coolant channels to control solidification rates in aluminium alloy.
- Melting & Casting: Selected aluminium alloy is melted in furnaces in temperatures between about 650 to about 750°C. When an appropriate fluidity & appropriate temperature is achieved by alloy, it is injected into die-cavity by high-pressure (usually between about 10 to about 175 MPa) to fill in detailed forms in motor vehicles.
- Solidification and ejection: Solidification is done rapidly following filling die with liquid aluminium. Solidification time is ideal to obtain required strength and grain structure. Die is parted off by ejection upon completion of solidification by ejection pins.
Post - Processing
- Trimming and deburring: Flash and runners in the castings are removed through trimming processes. Deburring is later carried out to remove burrs in edges to render the parts safe to fit correctly during assembly.
- Heat Treatment: Motor vehicles have certain die castings that can be treated by certain treatments by heating. Heat treatment is employed to achieve strength, hardness, and physical qualities in an attempt to achieve required requirements in motor vehicles.
- Surface Treatment: As yet another added value to corrosive strength and cosmetics, these castings can be treated through painting, powder coating, or anodizing. All these treatments have an added value to avoid wearing down in an automotive situation.
Quality Assurance
- Dimensional Inspection: Dimensions in casts are inspected by accurate instrumentation in the shape of Coordinate Measuring Machines (CMMs) to ensure that the part has appropriate tolerances to fit in motor vehicle assembly.
- Non-Destructive Testing: Internal defects including inclusions, cracks, and porosity are inspected through testing techniques including X-ray testing, ultrasonic testing, and magnetic particle testing to prevent destruction of castings.
- Mechanical Testing: Tension testing, testing for hardness, and testing by impact is conducted to validate the mechanical characteristics in castings. All these tests are referred to design specifications to validate the reliability and reliability of the car component.
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