China OEM Precision Die Casting 5G Telecom Radiator Housing | Top Suppliers & Factory Quality
Process
Aluminum die casting
Specifications & Characteristics
Equipment & Material: 400T aluminum die casting machine; ADC12 material
- a. Material handle: 20±2mm, furnace temperature: 670°±20°;
- b. The use of secondary items is not allowed;
- c. Verify through testing that the material composition is suitable and can be manufactured;
- d. After die casting, first piece confirmation is required.
Note
- a. Verify the filling quality of the surface. It’s not the bulge, it’s not the cold insulation, it’s not the lack of material in the pillars.
- b. Pay attention to the surface to prevent poor ejector pin crown, mold pulling or mold sticking.
- c. For non-machined surfaces and machined surfaces, the ejector pins are concave by 0-0.2 mm. The ejector pin must have a convex shape of 0-0.2 mm.
Take out the nozzle (saw nozzle) and pull out the slag bag
Equipment
A wooden stick / sawing machine
Things to Note
- a. Pay attention to the surface and don't damage it or use insufficient material.
- b. Adjust size and appearance
IPQC inspection (verify detailed dimensions in drawings)
Testing Instruments
Calipers, projection, three-dimensional modeling, visual appearance inspection
Precautions
Check dimensions against drawings and use accurate measuring equipment.
Product back plastic surgery
Tools
Hydraulic presses, forming tools and blade rulers
Precautions
Warning: The accuracy of the front of the product is within 0.25 mm.
CNC
Process & Equipment
- a: Use CNC processing to process the through-hole of the tooth hole, the end face of the inner cavity, and the end face of the peripheral heat dissipation tooth face.
- b: Deburring: In order to make the product smooth in appearance, the sharp corners are chamfered and deburred, and the non-machined ejector pins are sharpened and polished.
- c: Complete check
Tools and equipment include: wind grinders, files, flat-bottom milling cutters, drill bits, tap processing fixtures, and 120# sandpaper
Note
- a. Avoid over-cutting, leaving no sand holes, sharp edges, or missed processing; avoid scratches and burrs; and ensure smooth connection of the R corners.
- b. Control dimensional and shape tolerances to ensure that the processed surface finish reaches Ra 0.8.
- c. Regulation and non-regulation inspections.
- d. Verify product is flat relative to drawing.
- e. Handle items carefully to avoid deformation
Polishing (hand removal)
(Remove surface particles, slag bags, gate residues, and product wire caps.)
Note: Make sure the mold closing line is connected smoothly and there is no leakage in processing. Also, avoid sharp corners and jagged edges.
Outsourcing
Spraying & Testing
Process: Two-color spraying at different locations uses a combination of powder spraying and oil spraying.
Test instrument: Appearance visual inspection combined with colorimeter, film thickness meter, salt spray tester, hundred grid tester, alcohol resistance test, pencil test
Note
- a. No contrasting colors, dirt, exposed bottoms, dust accumulation, scratches or other issues; tinted and anti-bake fractals are clearly visible;
- b. The color is completely consistent with the sample;
IQC incoming material inspection/IPQC inspection
Note
- a. Verify surface condition after powder coating;
- b. Holes must be randomly inspected using pin gauges, pass gauges, and stop gauges.
100% inspection (verify how powder spraying appears)
Inspection Details
- a. 100% inspection of powder coated surfaces.
- b. Conduct irregular inspections for the purpose of powder coating performance testing.
Precautions
- a. There is no obvious color, dirt, exposed bottom, dust accumulation, scratches, etc. in the coloring and baking-resistant fractal areas;
- b. The color exactly matches the sample.
Dispensing glue, the width and height are asymmetrically centered at 1.0±0.1, and glued to the designated strip area.
Tools
Dispensing jigs and machines
Note
- a. The strips are even; they won't crack, pile up, pull, spill, deflect, blister, fall off, etc.
- b. Verify whether the glue cannot adhere or regenerate well, whether the glue strength is optimal, etc.
Composition of accessories and components
Assembly Process
- a. The assembly position of the heat dissipation copper bar corresponding to the glue assembly;
- b. Fix the M2.5*5 screws of the sheet metal parts in the appropriate position and push the copper block to dissipate heat;
Elements
- SE4450 adhesive
- Five copper heat sinks
- Three metal plates
- Six half-round screws, M2.5*5.
- Notes: a) Dispense glue into the copper row dispensing groove according to the sample; Make sure there are no loose or slipping teeth and that the locking screw is in a stable position.
Drying
Equipment & Instructions
Carefully arrange items on the baking line into 2 columns and 7 rows, for a total of 14 items. Bake at 150°C for 30 minutes.
Equipment: Dryer / Equipmen : dryer
Note
Leave enough space between products, be careful not to touch the tunnel door, hold lightly to avoid any bruises;
100% inspection: 100% appearance + packaging inspectio
Notes
- a. Appearance needs to be checked based on samples. There should be no dents, scratches or other blemishes on the surface and the glue application should be smooth and flawless!
- b. The tooth shape needs to match the pass gauge and stop gauge;
- c. Put the product into the knife card, cover the top of the knife card with a flat cardboard and package it.
FQC inspection
Instruments
Calipers, projectors, pin gauges, tooth gauges, visual and packaging inspection are all examples of testing instruments.
Prepare for a rainy day
If the measuring device is still within its calibration window.
Transportation
Note
- a. Confirm that the quantity matches the order.
- b. Label and stamp the outer box.
- c. Send reports on shipments.
OQC shipment inspection
Inspection Instruments
Calipers, projectors, tooth gauges, needle gauges, appearance, outer packaging inspection
Prepare for a rainy day
If the measuring device is still within its calibration window. Whether it meets both customer and SIP requirements.
Frequently Asked Questions (FAQ)
What material and machinery parameters are used in the die casting process?
We utilize a 400T aluminum die casting machine and ADC12 material. The process operates under a furnace temperature of 670°±20° with a material handle of 20±2mm.
How do you prevent surface defects during aluminum die casting?
We strictly monitor the filling quality of the surface to prevent cold insulation, bulges, and material shortage in the pillars. In addition, we check the ejector pin positioning (concave by 0-0.2 mm for non-machined and machined surfaces, and a convex shape of 0-0.2 mm) to prevent mold pulling and sticking.
What tolerances and surface finishes are expected from the CNC machining phase?
During the CNC machining phase, we control dimensional and shape tolerances to ensure the processed surface finish reaches Ra 0.8. We also ensure that the product flatness corresponds precisely to the engineering drawing.
What testing methods are used for the outsourcing spraying process?
The spraying quality is verified using a visual appearance inspection alongside specialized tools: a colorimeter, film thickness meter, salt spray tester, hundred grid tester, alcohol resistance test, and pencil test.
What are the temperature and layout specifications for the drying process?
Products are carefully arranged on the baking line in a configuration of 2 columns and 7 rows (totaling 14 items per batch). The parts are then baked in the dryer at 150°C for 30 minutes.
How do you guarantee measurement accuracy during FQC and OQC inspections?
For both FQC and OQC, we verify that all measurement instruments (including calipers, projectors, tooth gauges, and needle gauges) are actively within their calibration windows and comply fully with customer and SIP requirements.