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China Suppliers Aluminum Precision Die Casting Heat Sink Factory for 5G Applications
Process
Step 01
Aluminum die casting
Equipment & Material
Equipment: 1250T aluminum die casting machine, Material: ADC12
Process characteristics
- a. Furnace temperature: 670°±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.
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.
Step 02
Remove spout (Saw spout and knock out slag bag)
Equipment
sawing machine
Precautions
a. Pay attention to the surface without crushing or shortage of materials.
b. Control the appearance and size.
b. Control the appearance and size.
Step 03
IPQC inspection
Test tool
Caliper, projection, three-dimensional, visual inspection of appearance.
Precautions
Use measuring tools correctly and check dimensions according to drawings.
Step 04
SHAPING
Details
Back shaping
Equipment
Cutting edge ruler, shaping tooling
Precautions
Within 0.3mm of the front plane of the product
Step 05
IPQC inspection
Details
Visual inspection of appearance
Step 06
CNC
Details
Machining of internal cavity end faces, Backside holes, Side of one end, Hole through-hole
Equipment
CNC machine, flat-bottomed gong tool, Drill Bit, Tap machining jig
Precautions
a. Do not overcut, missed processing;
b. Surface attention must not be bruised, burrs; and
c. Ensure that the surface finish Ra0.8, size, shape and location tolerances.
b. Surface attention must not be bruised, burrs; and
c. Ensure that the surface finish Ra0.8, size, shape and location tolerances.
Step 07
Air tightness testing
Details
Test pressure value in 20kpa ~ 30kpa, stabilized pressure 20 seconds, test time 10 seconds, leakage control within 0.3kpa
Equipment
Airtight Tooling, Airtightness Test Equipment
Precautions
a. Do a good job on the product appearance surface protection, sealing groove parts without implementation of touch scratch;
b. Discover the phenomenon of air leakage in time to pick out the marking.
b. Discover the phenomenon of air leakage in time to pick out the marking.
Step 08
100% material 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.
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.
Step 09
Grinding
Details
Chamfering R-angle, deburring, thimble shaving on non-machined surfaces, polishing and smoothing the shape
Equipment
Equipment: Air grinder, 120# sandpaper
Note
Do not miss the processing, no sharp corners, burrs removed cleanly, connected to the R angle of the smooth.
Step 10
IPQC inspection:
Details
Visual inspection of appearance
Step 11
CLEANNING + Chemical conversion membrane + POWER 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;
b. Color according to the sample, uniform and consistent;
c. Powder thickness is uniform, no accumulation of tumors, no exposed bottom;
Step 12
IPQC inspection + Special Characteristics 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.
b. The holes need to be randomly inspected with a needle gauge/tested with a tooth hole pass gauge.
Step 13
Assembling-Press riveting
Details
D6 * 12 and D3 * 8 pins are clinched in the corresponding holes of the product.
Equipment
Pressure riveting jig, hydraulic press
Note
a, check the pin after loading without offset, fall off, the product surface without bulging, bruises ;
b. Check the height size after riveting.
b. Check the height size after riveting.
Step 14
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, and the glue dispensing shall be even and without 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.
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.
Step 15
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.
Step 16
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.
b. Label and stamp on the outer box
c. Provide a shipping report.
Step 17
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)
What materials and equipment are used in the die casting step?
The process utilizes a 1250T aluminum die casting machine and ADC12 material. The furnace temperature is strictly maintained at 670°±20°, with a material handle of 20±2MM.
What are the parameters for the air tightness test?
The test pressure is held between 20kpa and 30kpa. The pressure is stabilized for 20 seconds, with a testing time of 10 seconds. The leakage must be controlled within 0.3kpa.
What key quality checks are performed during CNC machining?
Operators must ensure there is no overcutting or missed processing. The surface must be free from bruises and burrs, and the surface finish must achieve Ra0.8 alongside correct dimensional and locational tolerances.
What surface treatments are applied to the products?
The products undergo grinding (chamfering R-angle, deburring, polishing, thimble shaving), cleaning, chemical conversion membrane application, and powder spraying to ensure complete, uniform color and thickness.
How is quality controlled before the final shipment?
Quality is strictly monitored via multiple inspection stages: IPQC inspections, 100% material inspection, FQC inspection, and a final OQC shipping inspection to verify that all dimensions and specifications align with SIP and customer requirements.