Core Advantages
Stable Electrical and Thermal Conductivity
The raw aluminum alloy's chemical composition is tested using a spectrometer during the feeding stage, strictly controlling impurity levels and maintaining a thermal conductivity above 150 W/m·K.
Precision Mold Design
Molds are modeled using CAD and manufactured using high-precision CNC and EDM processes. Cavity dimensional tolerances are controlled within ±0.01 mm, making them suitable for single-shot molding of complex electronic housings and connection structures.
High-Pressure Die Casting
Aluminum alloy is melted at 650–750°C and injection-molded using pressures exceeding 120 MPa. The metal fully fills the mold cavity, eliminating pores and underfilled areas.
Multiple Post-Processing
After die-casting, an automatic trimming machine removes excess material. The surface is sandblasted or polished before anodizing. The film thickness can be controlled to 10–15 microns. CMM dimensional inspection and X-ray non-destructive testing ensure quality.
Die Design and Production
- Precision Design: Computer-aided design (CAD) is used to design detailed three-dimensional (3D) prototypes of the dies to obtain precision design. Design is carried out taking individual requirements in sizes, surface finish, and functionality of electronic components into consideration.
- Tooling Production: Die production is carried out by taking recourse to superior-grade tool steels. Highly advanced machining processes, including computer numerical control (CNC) machining and electrical discharge machining (EDM) machining, to achieve die smoothness to a large extent and die accuracy
Die Casting Process
- Melting & Pouring: Aluminum alloy is melted in an oven between definite temperatures (most commonly between 650 - 750°C). When desired fluidity is achieved in the aluminium alloy, aluminium alloy is poured in the die-casting machine exactly.
- High-pressure injection: Liquid aluminium is injected in to the die cavity in high-pressure (most commonly between 10 to 175 MPa). This high-pressure fills every corner in the die cavity to obtain an exact die copy shape.
- Solidification and Cool down: Die bore is rapidly solidified by liquid aluminium during injection. Cool down is continued in an attempt to prevent shrinkage cavities and porosity.
Post - Processing
- Trimming & Finishing: Flash material in excess created during die-casting is peeled off. Cast faces are finished by polishing, sanding, or bead blasting to obtain required coarseness of the surface & cosmetic qualities.
- Heat Treatment: Heat can treat certain physical characteristics in die-casting aluminium by strengthening certain physical characteristics. This can be done by methods including solution heat treatment and artificial ageing.
- Surface Coating: Corrosion can be speeded by adopting certain practices of surface coating such as anodizing, powder coating, or electroplating in an attempt to have improved cosmetics.
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- Inspection Procedures: Many forms of inspections are carried out in production. Inspection to validate dimensional requirements is carried out by means of coordinate measuring machines (CMM) to validate that the castings have achieved needed tolerances. Internal defects can be exposed by non-destructive testing methods such as X-ray testing and ultrasonic testing.
- Performance Testing: Functional testing is conducted in die-casting products to ensure that they possess performance requirements needed by electronic products to which they should be applied, e.g., temperatures dissipation and conductance in an electric circuit.
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