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China OEM Aluminum Die Casting Heatsink for 5G Base Station - Trusted Suppliers and Factory Solutions
Process
1. Aluminum Die Casting
Equipment & Material
- Equipment: 400T aluminum die casting machine
- Material: ADC12
Process Characteristics
- a. Furnace temperature: 640°±20°, Material handle: 20±2MM;
- b. Secondary materials cannot be used;
- c. Test the material composition to confirm that it is OK and can be produced;
- d. First piece confirmation is required after die-casting.
Precautions
- a. The filling quality of the surface needs to be confirmed. No cold insulation, no bulging, or lack of material for the pillars.
- b. Pay attention to the surface to avoid sticking molds, drawing molds, or poor ejector pin convexity.
- c. The ejector pins are concave by 0-0.2mm for non-machine-added surfaces and 0-0.2mm for machine-added surfaces. The thimble needs to be convex 0-0.2mm.
2. Remove spout (Saw spout and knock out slag bag)
Equipment
- Wooden Stick / sawing machine / labor protection gloves
Precautions
- a. Pay attention to the surface without crushing or shortage of materials.
- b. Control the appearance and size.
3. IPQC inspection
Test Tools
- Caliper, projection, three-dimensional, visual inspection of appearance.
Precautions
- Use measuring tools correctly and check dimensions according to drawings.
4. SHAPING
Process Details
- Back shaping
Equipment
- Cutting edge ruler, shaping tooling
Precautions
- Within 0.2mm of the front plane of the product
5. IPQC inspection
Inspection Details
- Visual inspection of appearance
6. CNC
Process Details
- Machining main Inlet, main Dump Port Face, Backside, Perforated Overbore
Equipment
- CNC machine, flat-bottomed cutter, drill bit, tap processing fixture.
Precautions
- a. Do not over-cut or miss processing;
- b. Be careful not to scratch or burr the surface;
- c. Ensure the finish of the processed surface is Ra1.6, and the size and shape tolerances.
7. 100% material inspection
Inspection Details
- Visual inspection of appearance
Note
- a. The surface of the product should not be overcut, sand holes, lack of material. Burrs, and other undesirable phenomena;
- b. go-no go fixed gauges inspection;
- c. Test the flatness of the product according to the drawing;
- d. Hold the product lightly to prevent deformation.
8. Grinding
Process Details
- The sharp corners of the product are chamfered, deburred, non-machined ejector pins are sharpened, and polished to smooth the appearance.
Equipment
- Air grinder, 120# sandpaper
Note
- No processing should be missed, no sharp corners or burrs should be removed, and the R corners should be connected smoothly.
9. IPQC inspection
Inspection Details
- Visual inspection of appearance
10. Cleaning + Chemical conversion membrane + Powder Spraying
Precautions
- a. No different colors, dirty, not touching and scratching;
- b. Color according to the sample, uniform and consistent;
- c. Powder thickness is uniform, no accumulation of tumors, no exposed bottom.
11. IPQC inspection + Special Characteristics Inspection
Inspection Details
- Visual inspection of appearance
Note
- a. Confirm the surface quality after powder spraying;
- b. The holes need to be randomly inspected with a needle gauge/tested with a tooth hole pass gauge.
12. Full inspection of appearance + packaging
Equipment
- Carton, knife card, clapboard, bubble bag
Note
- a. The appearance shall be inspected according to the sample. The surface shall be free of dirt, scratches, dents and defects.
- b. The tooth pattern must comply with the go – no go fixed gauge inspection;
- c. The product is placed in the knife card, and then packaged.
13. FQC inspection
Test Tools
- Caliper, projection, needle gauge, tooth gauge, appearance and outer packaging inspection.
Precautions
- Whether the measuring tool is within the calibration period.
14. Shipping
Precautions
- a. Make sure the quantity is the same as order.
- b. Label and stamp on the outer box.
- c. Provide a shipping report.
15. OQC shipping inspection
Test Tools
- Caliper, projection, needle gauge, tooth gauge, appearance and outer packaging inspection.
Precautions
- Whether the measuring tool is within the calibration period. Whether it is consistent with SIP requirements and customer requirements.
Frequently Asked Questions (FAQ)
Q
What material and equipment are used for the initial aluminum die casting stage?
The process utilizes a 400T aluminum die casting machine and ADC12 material. The furnace temperature is strictly maintained at 640°±20° with a material handle of 20±2MM. Secondary materials are strictly prohibited.
Q
What surface finish and dimensional tolerances are required during CNC machining?
The CNC machining process must achieve a surface finish of Ra1.6. Operators must verify size and shape tolerances, prevent over-cutting or missed processing, and ensure no scratches or burrs are left on the surface.
Q
How is the quality of the powder spraying and chemical conversion membrane verified?
Quality is monitored via IPQC and Special Characteristics Inspections. Precautions include confirming uniform powder thickness with no accumulation of tumors or exposed bottom, ensuring colors match the sample, and verifying hole tolerances using needle and tooth hole pass gauges.
Q
What tools are utilized for FQC and OQC shipping inspections?
Both FQC and OQC inspections utilize calipers, projections, needle gauges, and tooth gauges to inspect dimensions, appearance, and outer packaging. All measuring tools must be verified to be within their calibration period.
Q
What packaging procedures are implemented to protect the finished products?
During the full inspection and packaging stage, products are placed inside a knife card setup and packed using cartons, clapboards, and bubble bags to ensure the surface remains free of dirt, scratches, dents, and defects.