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China Suppliers Factory OEM Aluminum A383 Die Cast Heat Radiator Backplate for Enhanced Performance
Process Workflow
Step 01
Aluminum Die Casting
Machine & Material
280T aluminum die casting machine; Material: ADC12 (US-383/Russia-AJ16/German-AlSi8Cu3/UK-LM2/Italy-4520/Eu-ENAC-46400)
Process Characteristics
- Furnace temperature: 640°±20°, Material handle: 20±2MM;
- Secondary materials cannot be used;
- Test the material composition to confirm that it is OK before being produced;
- First piece confirmation is required.
Note
- Confirm the filling quality of the surface. No cold insulation, no bulging, or lack of material for the pillars.
- Pay attention to the surface to avoid sticking molds, drawing molds, or poor ejector pin convexity.
- 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
Nozzle & Slag Bag Removal
Tools
Wooden Stick
Things to Note
- Pay attention to the surface and don't damage it or use insufficient material.
- Manage size and appearance.
Step 03
IPQC Inspection
Testing Instruments
Three-dimensional, appearance visual evaluation, projection, calculator
Precautions
Please take the following precautions: Check dimensions against drawings and use accurate measuring equipment.
Step 04
Grinding
Process Detail
Removal of mold line fringes, surface particles, slag packs and sprue residues.
Equipment
Air grinder, 120# sandpaper
Note
Do not miss machining, no sharp corners, burr removal clean, mold line connection smooth.
Step 05
Drilling
Process Detail
Drill a hole through one wall D3.5+0.15/-0 on each side face.
Equipment
Small drilling machines, specialized jigs
Note
- Do not overcut, missed processing;
- Surface attention must not be bruised, burrs;
- Ensure that the surface finish Ra0.8, size, shape and location tolerances.
Step 06
Sand Blasting
Process Detail
The surface of the product is sprayed with 80# brown corundum sand.
Equipment
Sand blasting machines
Note
Spray the inner cavity surface first, and then spray the heat dissipation tooth surface; pay attention to the large plane on the heat dissipation tooth surface after sandblasting does not allow scratches, leakage of spraying, cold lines!
Step 07
Shaping
Process Detail
Backside shaping
Equipment
Knife-edge ruler, shaping jig
Note
Backside plane within 0.15mm.
Step 08
Electrophoresis
Note
- The coloring area is obvious, without different color, dirt, exposed bottom, accumulated paint, bubbles, touching and scratching;
- Color according to the sample, uniform and consistent.
Step 09
IPQC Inspection
Equipment
Appearance visual inspection + film thickness meter + colorimeter + salt spray tester + hundred grid test tool + alcohol resistance test + pencil test
Note
- Confirmation of surface quality after electrophoresis;
- Go-no go fixed gauges inspection, tooth hole through stop gauge detection.
Step 10
Full Material Inspection
Process Detail
Visual inspection of appearance
Note
- The surface should not be overcut, sand holes, lack of material, burrs, and other undesirable phenomena;
- GO - NO GO FIXED GAUGES inspection;
- Test the flatness of the product according to the drawing;
- Hold the product lightly to prevent deformation.
Step 11
Shaping: Backside Shaping
Equipment
Knife-edge ruler, shaping jig
Note
Backside plane within 0.2mm.
Step 12
Full Inspection of Appearance + Packaging
Note
- The electrophoresis surface is free of different color, dirt, exposed bottom, accumulated paint, bubbles, touching and scratching;
- The color is uniform and consistent according to the sample;
- The through-hole should be in accordance with the inspection of through-hole gauge.
- The product is put into the knife card, and the upper layer is covered with flat cardboard and then packed into boxes.
Step 13
FQC Exam
Test Tools
Caliper, projection, needle gauge, tooth gauge, appearance and outer packaging inspection
Note
Whether the measuring tool is within the calibration period.
Step 14
Shipping
Note
- Confirm that the quantity matches the order.
- Label and stamp the outer box.
- Provide a shipping report.
Step 15
OQC Shipping Inspection
Testing Instruments
Calipers, projectors, pin gauges, tooth gauges, outer packaging inspection, etc.
Note
If the measuring device is still within its calibration window. Whether it meets both customer and SIP requirements.
Frequently Asked Questions (FAQ)
What alloy material is used during the Aluminum Die Casting process?
We use ADC12 aluminum alloy. This material is equivalent to US-383, Russia-AJ16, German-AlSi8Cu3, UK-LM2, Italy-4520, and Eu-ENAC-46400.
What are the furnace parameters and material handling rules?
The furnace temperature is strictly maintained at 640°±20° with a material handle of 20±2MM. Additionally, secondary materials cannot be used, and material composition must be confirmed before production.
What quality standards apply to the Electrophoresis surface treatment?
The electrophoresis surface must be free from color variations, dirt, exposed substrate, paint accumulation, bubbles, or scratches. The color must be uniform and consistent according to the approved sample.
What tolerances are required during the Shaping steps?
During the initial backside shaping (Step 7), the backside plane must be within 0.15mm. In the subsequent backside shaping (Step 11), the backside plane must remain within 0.2mm.
How are products protected during packaging and shipping?
Products are put into protective knife cards, and the upper layer is covered with flat cardboard before being packed into boxes. Products must be handled lightly to prevent deformation.
What testing instruments are used for quality inspections?
Quality control relies on calipers, projectors, pin/needle gauges, tooth gauges, film thickness meters, colorimeters, salt spray testers, hundred grid test tools, alcohol resistance tests, and visual inspection tools. All measuring devices must be within their valid calibration window.