ALUMINUM ALLOY MANUFACTURING PROCESS - Zhejiang Ningbo Hexin specializes in low-pressure casting, gravity casting, die casting mold manufacturing, aluminum casting plant

Chrome-free surface passivation for aluminum alloys

2025-03-26

Applications of Aluminum Aluminum is the most productive and widely used metallic material among non-ferrous metals. It is second only to steel in terms of production of structural metallic materials. All-aluminum engines The advantage of cast aluminum blocks in die-casting production is their light weight, which enables fuel savings through weight reduction. In an engine of the same displacement, the use of an aluminum block engine reduces weight by about 20 kilograms. For every 10% reduction in the car's own weight, fuel consumption can be reduced by 6% to 8%. Disadvantages of chromate surface treatment The waste tank liquid of chromate treatment method contains a large amount of hexavalent chromium ions, and according to GB 8978--1996 Comprehensive Sewage Discharge Standard, the concentration of hexavalent chromium in the waste tank liquid is not more than 0.5mg/L. However, hexavalent chromium ions have carcinogenic effect on human body. Long-term exposure to hexavalent chromium compounds can lead to...

Casting vs. machining: how do we choose?

2025-03-19

As a core member of Ningbo Hersin's casting technology team, I have been working in the field of high pressure casting, low pressure casting, gravity casting and aluminum materials for more than 20 years, and have led the process development of hundreds of industrial projects. Whenever a customer raises the question of "how to choose between casting and machining", my answer is always: "There is no absolute advantage or disadvantage, only the most suitable combination of technologies for the scene." The following technical principles, practical experience and industry trends in three dimensions, in-depth analysis of the core differences between the two and the logic of choice. What is casting? Casting is melting metal, manufacturing casting, and pouring molten metal into the casting, solidification to obtain a certain shape and performance of the casting molding method. Casting and other parts molding process, compared with low production costs, process flexibility, almost independent of the size and shape of the part...

In-depth analysis of the entire friction welding process

2025-03-08

Friction welding definition Friction welding is the use of relative friction movement of the weldment to produce heat to achieve a reliable connection between the materials of a pressure welding method. The welding process is under the action of pressure, the relative movement of the material to be welded between the friction, so that the interface and its nearby temperature rises and reaches a thermoplastic state, with the role of the top forging force interfacial oxide film broken, the material undergoes plastic deformation and flow, through the interface element diffusion and recrystallization of the metallurgical reaction and the formation of joints. Friction welding principle Two round section of the metal workpiece in the friction welding before, respectively, can be clamped in the rotating chuck and can move forward to pressurize the chuck. At the beginning of welding, the workpiece 1 rotates at high speed, the workpiece 2 moves in the direction of the workpiece 1 and contacts, and a large enough friction pressure is applied to start the friction heating process. After a period of friction, the joint...

Machining Basics

2025-02-27

Machining Machining as the core technology of modern manufacturing industry, through lathe, milling machine, grinder and other professional equipment on metal, plastic and other workpieces for cutting, grinding, drilling and other processes, precise control of the geometry of the parts, the structure of the dimensions and surface finish, to ensure that from the automotive engine components to the aerospace precision parts of the whole field of manufacturing needs. With the deep integration of CNC technology and automated production lines, the machining process has realized the transformation and upgrading from traditional manual operation to intelligent programming control, which improves machining efficiency while effectively controlling production costs. The quality control system that strictly follows international standards ensures process stability in mass production through real-time monitoring of tool wear status and optimization of machining parameters. Under the current trend of Industry 4.0, machining is moving towards flexible...

What is the difference between aluminum extrusion and aluminum die casting?

2025-02-25

As an engineer deeply involved in aluminum alloy forming for more than 20 years, I am often asked about the core differences between aluminum extrusion and aluminum die casting. In this article, I will combine the high-pressure/low-pressure/gravity casting practical experience to make a systematic comparison from material science, process principle to business decision. What is aluminum extrusion? Aluminum extrusion is a solid-state process of extruding through a die, belonging to solid-state plastic forming, commonly used in the production of assembly line aluminum profiles, heat dissipation aluminum parts and so on. At its core, aluminum rods heated to a plastic state (400-500°C) are fed into an extruder and forced through a die of a specific cross-sectional shape to form a continuous profile, which can be used to manufacture long-sized products such as door and window frames, rails, and other long products (longitudinal lengths of up to 10 meters or more). Advantages of Aluminum Extrusion Aluminum extrusion products are lightweight, corrosion-resistant, and have low die investment costs (about 30,000...

The history of CNC lathe development: from basic turning to the technological revolution in the manufacture of complex parts

2025-02-24

As a living fossil of industrial civilization, the evolution of CNC lathe maps the eternal pursuit of human precision manufacturing. From 1300 BC Egyptian craftsmen with rope-driven wooden rotary bed, to the 21st century equipped with AI algorithms five-axis intelligent machine tools, the technology has always been in the redefinition of the "precision" of the boundaries of the industrial revolution period of steam-powered lathe will be compressed to 0.1mm processing error, while the modern CNC system through the scale closed-loop control has achieved 0.0000mm. During the industrial revolution, steam-powered lathes compressed machining errors to 0.1mm, while modern CNC systems have realized microscopic control of 0.001mm through closed-loop scale control. Especially in the field of high-performance aluminum alloy parts manufacturing, the multi-axis synergy of CNC lathe has completely changed the traditional process: Take the new energy vehicle motor shell as an example, the composite machining of its heat dissipation tooth piece and bearing bit can be completed at one time in the integrated Y-axis power turret of the CNC system, which can improve the efficiency of 400% compared with the traditional processing efficiency in sequence, and the same ...

The definitive guide to centrifugal casting technology: Principles/Processes/Industrial Applications Analysis

2025-02-23

What is centrifugal casting? Centrifugal casting is a liquid forming process in which liquid metal is poured into a rotating mold by the centrifugal force generated by the rotating mold (up to 150 times the force of gravity) and rotated at high speeds (usually 250 to 1500 r/min) so that it fills the mold and solidifies under the action of centrifugal force to form a casting. The process is particularly suitable for the manufacture of marine engine cylinder liner, aerospace and high temperature parts and other harsh working conditions products - more measured data show that the centrifugal casting aluminum alloy pieces of tensile strength than the traditional sand casting to enhance the 25% or more. How Centrifugal Casting Works The centrifugal casting process begins with the injection of liquid metal into a rotating, high-temperature mold. Depending on the specific requirements of the design, the mold can rotate vertically or horizontally. During this process, centrifugal force evenly distributes the liquid metal at a pressure close to several times the force of gravity...

Zinc die casting and aluminum die casting core technology comparison

2025-02-19

In the modern manufacturing industry under the wave of vigorous development, die-casting technology with its high efficiency, high precision characteristics, in the automobile, electronics, aerospace and many other fields widely used. Zinc die casting and aluminum die casting as the two main stream of die casting process, like two bright pearls in the manufacturing industry, each exudes a unique light, has different advantages and applicable scene. For engineers, in product design and production, accurate selection of die casting technology is crucial, which is directly related to the product performance is excellent, cost control is reasonable, production efficiency can meet expectations. This article will be in-depth analysis of zinc die casting and aluminum die casting technology, from the material characteristics, process parameters, cost composition and other dimensions of the comparison, for engineers to provide a comprehensive, detailed selection decision-making reference. Technical principle (a...

Rapid Tooling: An Innovative Solution to Accelerate Product Development and Manufacturing

2025-02-14

In this era of rapid technological iteration, the manufacturing industry is experiencing a profound change from "scale first" to "agile and efficient". Rapid mold (Rapid) Foreword: China's mold manufacturing predicament and breakthrough As a deep-rooted foundry industry for 23 years of engineers, I (He Xin) witnessed China from the mold importing country to the metamorphosis of independent innovation. In Ningbo, this mold industry gathering place, we have experienced the traditional steel mold development cycle is long, high cost of trial and error pain, but also experienced the revolutionary breakthroughs brought about by rapid mold technology. This paper will combine the high-pressure casting, low-pressure casting and other practical application scenarios, revealing the key technical logic of rapid tooling in the manufacture of aluminum alloy parts. 1, the essence of fast mold: not a compromise, but accurate matching 1.1 The three major pain points of the traditional mold 1.2 fast mold technology ...

Mold flow CAE (fluid simulation technology) casting applications

2025-02-11

Nowadays, with the development of computer software, artificial intelligence, the accuracy and credibility of simulation analysis software, the application of mold flow analysis software in the foundry industry is more and more common. cae simulation technology is widely used in the development of casting molds and product production. Numerical computation theory and GPU parallel technology breakthroughs, the modern casting process has entered the era of digital simulation and physical experimentation dual-wheel drive. This paper is based on the author in the field of high-pressure / low-pressure / gravity casting 23 years of engineering experience, combined with typical process cases, in-depth analysis of the application of CAE technology in the actual production of mold flow points. Casting simulation technology principles and engineering boundary conditions The nature of the casting process is a metal melt in the complex constraints of the unsteady state heat and mass transfer process, the numerical simulation needs to be established to include the Navier-Stokes equations, the ability to ...

Understanding CNC Machining: What You Need to Know

2025-02-01

Computer numerical control (CNC) is a manufacturing and processing technology, through the computer processing software pre-written program, in the CNC system through the computer control of machine tool trajectory, processing speed and other parameters, control machinery and tools according to the command like a robot to carry out a series of complex mechanical movement, the workpiece accurately carried out by the processing, revolutionized the manufacturing industry. The global CNC machine tools market is expected to grow significantly, valued at more than $128 billion by 2028.The rapid growth of CNC has surfaced the shift in manufacturing towards digitalization and precision. What is CNC? Definition and Basic Concepts CNC machining, or Computer Numerical Control machining, is a manufacturing technology that involves precision cutting and shaping of materials through computer-controlled machine tools. You can think of it as an automated method of machining that is able to follow pre...

Aluminum alloy gravity casting common defects and preventive measures

2025-01-21

Gravity casting is in the casting process, the first solidification of the metal liquid due to thermal expansion and contraction volume contraction, need to rely on the upper part of the solidified metal liquid gravity to replenish, to complete the effect of shrinkage. Gravity casting solidification mode for the order of solidification, is the whole part in the solidification of the solidification in accordance with a certain sequence of successive solidification, relatively backward solidification position can be complementary shrinkage of the relative front of the solidification position, so that the final casting defects are concentrated in the last cooling parts (risers, gates position), to get qualified production castings. Gravity casting aluminum alloy wheel castings solidification sequence: rim - spokes - center hub (bevel) - manifold cone - - gate (riser) casting -Gate (riser) Casting process design parameters include machining allowances, process allowances (risers and other remedial shrinkage locations), metal shrinkage (shrinkage coefficients), and draw slopes, cooling system...

Die casting and sand casting: how to correctly select the most suitable casting process for you

2025-01-13

In manufacturing, casting is one of the key technologies used to produce components. Whether for automobiles, appliances, or industrial machinery, the casting process provides a robust and reliable solution. Die casting and sand casting are the two most common casting methods, and they differ significantly in many ways. Choosing the right casting process will have a direct impact on product cost, accuracy, productivity and material suitability. In this article, we will introduce these two casting process, and help you make the best choice for your project. Die casting and sand casting: process introduction 1. what is die casting? Die casting is a casting process that injects molten metal into a precision mold cavity through high pressure. It is commonly used in aluminum, zinc, copper, magnesium and other alloys casting, especially suitable for mass production of complex shapes, precision...

Aluminum alloy die casting applications in the automotive industry: Advantages and prospects for custom aluminum casting components

2025-01-08

Preface Aluminum alloy, as an ideal material, has been more and more widely used in automobile manufacturing. Aluminum alloy die casting technology has become an indispensable manufacturing technology in the automotive industry due to its advantages of high precision, high strength and high efficiency. It is expected that by 2025, the market share of aluminum alloy die casting in the automotive industry will continue to grow, especially in the field of electric vehicles and high-performance vehicles, aluminum alloy die casting will play an increasingly important role. This article will delve into the application of aluminum alloy die casting in the automotive industry, analyze why aluminum die casting has become a widely used process in automotive manufacturing, and explain its specific application in automotive parts and components, to help you understand how customized aluminum die casting can contribute to the innovation and development of the automotive industry. History The aluminum die casting process originated in the early 20th century and was rapidly applied...

Low Pressure Die Casting Principles and Applications

2025-01-07

What is low pressure die casting? Aluminum low pressure die casting (LPDC) is to make the liquid metal under pressure to complete the filling cavity and solidification process two get castings of a casting method. Due to the existence of a certain pressure but far lower than the pressure of high pressure die casting (the highest pressure is only for high pressure die casting 1%), low pressure die casting pressure range in (20 ~ 60kPa), with its role in the pressure of small speed is slow, but also be able to manufacture a more complex internal hollow products (hollow part of the need for the sand core subsequent to the removal of the so-called low-pressure sand casting), and the principle of its role is more close to the aluminum Casting, so it is also called aluminum low pressure casting. Low-pressure die-casting process: in the impermeable crucible, through the pipeline into the compressed dry gas, molten aluminum in the role of gas pressure, along the rise of the liquid tube (crucible in the middle of the...

CNC machining 20 years of combat: the teacher hand in hand to teach you to play the CNC machine tools

2024-12-26

I am Ningbo He Xin dry more than 20 years old CNC, from the apprentice to touch the iron chips to take the apprentice to adjust the five-axis, the hand of the parts less than hundreds of thousands of pieces. Today with the gang nagging CNC machining those doorways, guaranteed that you can listen to less detours! CNC machine tools in the end where strong? In the early years we do manual milling machine, do 10 pieces a day are difficult. Now with five-axis linkage, complex surfaces of the aviation blade can be 50 pieces a day! Precision is dry from millimeter level to hairline thickness (± 0.01mm), the last time to German customers to do precision bushings, three-coordinate test report out, foreigners thumbs up. What is in the belly of the machine tool? Teacher's unique secret headache problem soil solution serious program thin-walled parts deformation pad kraft shock-absorbing segmented processing + thermal stress simulation deep hole drilling bias first play the center hole and then change the drill gun...

Die casting technology: a key manufacturing process for turning visions into reality

2024-12-24

In modern manufacturing, the die-casting process is regarded as an important means of manufacturing precision metal parts. It injects molten metal into precision molds at high pressure, enabling the production of complex shaped metal parts, which are widely used in automotive, electronics and other fields, supporting the technological development of several leading industries. This article will provide an in-depth analysis of the core processes, material selection and applications of the die casting process, and how this process can achieve innovation and excellence in manufacturing. What is die casting? Die casting is a highly efficient and precise method of casting metal, utilizing reusable molds to produce complex shaped metal parts. Unlike traditional casting processes, die casting injects molten metal into a mold under high pressure, making it particularly well-suited for high-volume production and providing high precision, repeatability, and excellent surface finishes. The die casting process was originally...

Aluminum Alloy Extrusion: Principles, Process Optimization and Outlook for Future Applications

2024-12-04

Classification of Aluminum Alloys Classification of Cooked Aluminum (a)Classification by Alloying Elements1.×××× indicates pure aluminum system of 99.0% or more purity of aluminum parts and panels 85/KG2.××× indicates aluminum-copper alloys3.×××× indicates aluminum-manganese alloys4.××× indicates aluminum-silicon alloys5.××× indicates aluminum-magnesium alloys (imported from Switzerland)6.××× indicates aluminum-magnesium-silicon alloys T5 6063 60617.×××× indicates aluminum-zinc-magnesium alloys8.××× indicates alloys of systems other than those mentioned above9.××× indicates alternate classification number (b) Classification by strengthening mechanism1.Strain-hardening aluminum alloys: 1××××, 3××××, 4××××, 5××××2.Heat-treatable strengthened aluminum alloys: 2×××, 6××××, 7××× Classification of Cast Aluminum Alloys Al (Minimum Al content) 99.0% or more)1 × × × × Al-Cu alloy2 × × × × Al-Si alloy Containing Cu and Mg or Mg3 × × × × Al-Si alloy3 ××-×Al-Mg alloy4 ××...

Differential pressure casting process and principle

2024-11-27

What is differential pressure casting? Differential pressure casting (also known as counterpressure casting), is the liquid metal in the differential pressure, filled to a certain pressure in advance of the casting, crystallization, solidification and obtain castings of a process. It is a combination of two processes: low-pressure casting and crystallization and solidification under pressure. The process can be based on the shape of the casting, process requirements and casting characteristics, adjust the pressure in the cavity, so that the liquid metal flow into the casting under control, and in the casting does not change the state of the casting force conditions, so that the casting solidified under higher pressure, the production of other forming methods difficult to pour complex, thin-walled, whole aluminum castings, to solve the casting casting technology in a major key. The working principle of differential pressure casting: A. Inflatable B. Pressurization method C. Decompression method The casting is placed in the upper pressure cylinder, the crucible furnace is placed in the lower pressure...

Aluminum alloy processing technology

2024-10-21

As the most widely used non-ferrous metal material, aluminum alloy, by virtue of its unique performance advantages, continues to expand its application in the fields of architectural decoration, transportation, aerospace and so on. According to statistics, the variety of global aluminum alloy products has exceeded 700,000, and the reasonable choice of its 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 paper systematically analyzes the eight core machining processes and six surface treatment technologies, and deeply analyzes the causes of machining deformation and response strategies. ! [Aluminum alloy processing technology application scenario] I. Aluminum alloy core performance advantages II. Comparative analysis of the eight core processing technology (a) Cold stamping process (b) Tensile molding process (c) Precision machining (d) Laser cutting process (e) Special casting process Process category ...

Sand casting process

2024-10-08

What is sand casting? Sand casting , also known as sand casting, is a time-honored method of casting process with a wide range of applications across the globe. It is a process of producing castings by using clay-bonded sand (or sand molds made of other materials such as gypsum and silicone resin) as the molding material. The principle is to take advantage of the softness and ease of molding of the sand mold by pouring molten metal into the sand mold, and then crushing the sand mold after the metal has solidified in order to obtain the desired casting. Applied in a variety of metals, common aluminum sand casting, iron sand casting, copper sand casting, now let the aluminum alloy casting factory located in China Ningbo He Xin for everyone to explain the sand casting process. Conventional process flow of sand casting production Sand casting process (1) Preparation of molding sand and core sand The molding material for sand casting is mainly used for...

Aluminum alloy gravity casting, high-pressure casting, low-pressure casting process introduction awareness

2024-09-04

Gravity casting introduction: gravity casting refers to the aluminum liquid in the earth's gravity under the action of gravity injection casting process. Broad gravity casting gravity casting is divided into sand casting, metal type (steel mold) casting, disappearing mold casting. ; Narrow gravity casting refers to the metal type casting. Metal casting is divided into upright hand casting, tilted casting is now most commonly used metal mold (steel mold) casting. The mold is made of heat-resistant alloy steel, casting aluminum castings strength, size, appearance are higher than other casting processes. Aluminum liquid for gravity casting is generally poured manually into the gate, relying on the self-weight of the metal liquid to fill the cavity, exhaust, cool, and open the mold to obtain the sample. The process is generally: aluminum liquid melting, pouring, exhaust, cooling, mold opening, cleaning, heat treatment, processing. Aluminum alloy gravity casting is characterized by ...

Difference between casting flange and forging flange

2024-09-03

Casting flange Casting flange, blank shape and size accuracy, small processing, low cost, but there are casting defects (porosity. Cracks. Inclusions); casting internal organization streamline is poor (if it is cutting parts, streamline is poor); forging flange is generally lower than casting flange, low carbon content, not easy to rust. Forging streamline good, dense organization, mechanical properties better than casting flange; if the forging process is not appropriate, the grain will be large or uneven, there will be hardening cracks, forging cost is higher than casting flange. Forgings can withstand higher shear and tensile forces than castings. The advantages of castings are complex shape, low cost; uniform internal organization, no casting holes, inclusions and other harmful defects; casting flanges and forging flanges, such as centrifugal flanges, belong to one of the casting flanges. &nb...

Semi-solid metal casting process

2024-08-03

1, Overview Since 1971, the Massachusetts Institute of Technology's D.B. Spencer and M.C. Flemings invented a stir casting (stir cast) a new process, that is, the use of rotating double barrel mechanical stirring method to prepare a Sr15% Pb rheological slurry since the semi-solid metal (SSM) casting process technology has experienced more than 20 years of research and development. The alloys prepared by stir casting are generally known as non-dendritic organization alloys or called Partially Solidified Casting Alloys (Partially Solidified Casting Alloys). Products using this technology have a strong vitality due to their high quality, high performance and high alloying characteristics. In addition to applications in military equipment, it has begun to focus mainly on key components for automobiles, for example, for automobile wheels, which can improve performance, reduce weight, and lower scrap rates. This ...

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