Aluminum alloy processing technology

As the most widely used non-ferrous materialaluminumWith its unique performance advantages, the application in the fields of building decoration, transportation and aerospace continues to expand. According to statistics, the global aluminum alloy products have exceeded 700,000 types, and the reasonable choice of processing technology and deformation control is directly related to product quality. Based on the author's more than 20 years of experience in the casting industry, this article systematically analyzes eight core machining processes and six surface treatment technologies, and deeply analyzes the causes of machining deformation and response strategies.

! [Schematic diagram of aluminum alloy machining process application scenarios]

I. Aluminum alloy core performance advantages

1. Lightweight AdvantageDensity is only 2.7g/cm³, equivalent to 35% of steel, significantly reducing structural weight.
2. Excellent molding performanceElongation up to 30% or more, supports extrusion/stretching and other complex molding processes.
3. Outstanding corrosion resistance: Natural oxide film + anodized treatment, corrosion resistance better than ordinary steel
4. Intensity adjustable: 600 MPa tensile strength by alloying/heat treatment
5. Proven surface finish: Anodizing process yield exceeds 95% for colorful tinting
6. High recycling rate: Energy consumption of recycled aluminum is only 5% of primary aluminum, which is in line with the requirements of sustainable development.

II. Comparative analysis of the eight core processing techniques

(i) Cold stamping process

• Process Characteristics: Adopt 200-2000 tons punching machine, accurate control of wall thickness by die clearance (±0.1mm)
• Applicable Scenarios: Cylindrical parts/shaped parts (e.g. automotive ABS valve body)
• Economic analysis: Tooling costs reduced by 40%, but labor costs accounted for 25%

(ii) Stretch molding process

• technological breakthroughMulti-station continuous molds for 15 successive deformations (e.g. laptop case)
• Precision control: Dimensional tolerances up to IT8, surface roughness Ra0.8μm
• return on investment: Mold development cycle of 8-12 weeks, suitable for mass production of more than 100,000 pieces

(iii) Precision machining

• Technology Matrix:
  • 5-axis linked machining center: surface accuracy ±0.01mm
  • Slow-feeding wire-cutting: machining accuracy of ±0.003mm
  • Coordinate grinding machine: Hole diameter tolerance control ±0.002mm
• Innovative applications: Aero-engine impeller machining using mill-turn technology

(iv) Laser cutting process

• parameter optimization:
  • Fiber laser: power 6kW, cutting speed 30m/min
  • Nitrogen-assisted: incision oxide layer <5μm
• typical caseNew Energy Vehicle Battery Tray Cutting Yield Increased to 99.2%

(v) Special casting processes

Process Type	Dimensional accuracy	surface roughness	Minimum wall thickness	Applicable Scenarios
pressure casting	CT6	Ra3.2	1.2mm	Automotive Engine Casing
investment casting	CT4	Ra1.6	0.8mm	Aviation hydraulic components
Low-pressure casting	CT5	Ra6.3	2.5mm	Wheel manufacturing
vacuum die casting	CT5	Ra2.5	1.0mm	5G Base Station Heat Sink

(vi) Powder metallurgy technology

• Technological innovations: Metal Injection Molding (MIM) enables fabrication of 0.5mm miniature parts
• performance enhancementRelative density up to 98%, tensile strength up to 30%.
• Application Expansion: Intelligent wearable device hinge parts volume production exceeded one million pieces level

(vii) Injection molding process

• Technical Parameters:
  • Feeding fluidity: ≥150mm/10s
  • Degreasing efficiency: solvent degreasing + thermal degreasing combination process
• Industry Applications: Zero Defect Delivery of Joint Components for Medical Devices

(viii) Squeeze casting technology

• Process AdvantagesLiquid die forging for 99.51 TP3T tissue densities
• parameter controlSpecific pressure 80-150MPa, holding time 0.5-2s/mm
• typical case: Military Armor Plate Elastic Resistance Enhancement 40%

Three, six surface treatment technology mapping

1. Anodizing technology:
   • Hard anodizing: film thickness 50-150μm, hardness HV400
   • Micro-arc oxidation: breakdown voltage 300V, forming a ceramicized surface
   • Typical case: UAV shell corrosion resistance life of more than 1000h
2. Two-color anodizing process:
   • Masking accuracy: ±0.05mm
   • Color difference control: ΔE<1.5
   • Application examples: high-end cell phone frame two-color gradient effect
3. High-gloss cutting technology:
   • Spindle speed: 20000-50000rpm
   • Tool life: diamond tools can machine 3000 pieces
   • Innovative application: 8K TV bezel mirror effect
4. Nano Spraying Process:
   • Film thickness: 20-50μm
   • Adhesion Test: Scratch Method Grade 0
   • Technological Breakthrough: Successful Development of Self-Repairing Coatings

Four, processing deformation control five strategies

Symmetric processing method: deformation reduction 60%

Residual Stress Control:

Vibration aging treatment to eliminate internal stresses above 90%

Optimization of heat treatment process: graded aging temperature control ±3°C

Optimization of cutting parameters:

High speed cutting: line speed 300-800m/min

Micro lubrication: oil mist volume control at 5-15ml/h

Clamping system improvement:

Flexible fixture repeatability ±0.005mm

Vacuum clamping force distribution uniformity >95%

Temperature field control:

Low temperature cutting: -196℃ liquid nitrogen cooling

Online temperature measurement: infrared temperature measurement accuracy ±1℃.

Process route optimization:

Separation of roughing and finishing: margin control at 0.2-0.5mm