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China Suppliers Factory OEM Die-Casting Aluminum A383 Heat Radiator Backplate for Superior Thermal Management
Process
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)
Material: ADC12 (US-383/Russia-AJ16/German-AlSi8Cu3/UK-LM2/Italy-4520/Eu-ENAC-46400)
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 before being produced;
d. First piece confirmation is required.
b. Secondary materials cannot be used;
c. Test the material composition to confirm that it is OK before being produced;
d. First piece confirmation is required.
Note
a. Confirm the filling quality of the surface. No cold insulation, no bulging, or lack of material for the pillars.
b. Avoid sticking molds, drawing molds, or poor ejector pin convexity.
c. Ejector pins: concave 0-0.2mm for non-machine-added surfaces and 0-0.2mm for machine-added surfaces. Thimble needs to be convex 0-0.2mm.
b. Avoid sticking molds, drawing molds, or poor ejector pin convexity.
c. Ejector pins: concave 0-0.2mm for non-machine-added surfaces and 0-0.2mm for machine-added surfaces. Thimble needs to be convex 0-0.2mm.
Step 02
Nozzle & Slag Bag Removal
Tools
Wooden Stick
Things to Note
a. Pay attention to the surface; don't damage it or use insufficient material.
b. Manage size and appearance.
b. 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
Objective
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
Objective
Drill a hole through one wall D3.5+0.15/-0 on each side face.
Equipment
Small drilling machines, specialized jigs
Note
a. Do not overcut or miss processing;
b. Avoid surface bruises and burrs;
c. Ensure surface finish Ra0.8, size, shape, and location tolerances.
b. Avoid surface bruises and burrs;
c. Ensure surface finish Ra0.8, size, shape, and location tolerances.
Step 06
Sand Blasting
Objective
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, or cold lines!
Step 07
Shaping
Process
Backside shaping
Equipment
Knife-edge ruler, shaping jig
Note
Backside plane within 0.15mm.
Step 08
Electrophoresis
Process
Surface Electrophoretic Coating
Note
a. The coloring area is obvious, without different color, dirt, exposed bottom, accumulated paint, bubbles, touching, and scratching;
b. Color according to the sample, uniform and consistent.
b. 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
a. Confirmation of surface quality after electrophoresis;
b. Go-no go fixed gauges inspection, tooth hole through stop gauge detection.
b. Go-no go fixed gauges inspection, tooth hole through stop gauge detection.
Step 10
Full Material Inspection
Method
Visual inspection of appearance
Note
a. The surface should not be overcut, sand holes, lack of material, burrs, or 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 11
Shaping (Backside)
Equipment
Knife-edge ruler, shaping jig
Note
Backside plane within 0.2mm.
Step 12
Full Inspection & Packaging
Process
Full inspection of appearance + packaging
Note
a. The electrophoresis surface is free of different color, dirt, exposed bottom, accumulated paint, bubbles, touching, and scratching;
b. The color is uniform and consistent according to the sample;
c. The through-hole should be in accordance with the inspection of through-hole gauge;
d. The product is put into the knife card, and the upper layer is covered with flat cardboard and then packed into boxes.
b. The color is uniform and consistent according to the sample;
c. The through-hole should be in accordance with the inspection of through-hole gauge;
d. 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
Status
Ready for dispatch
Note
a. Confirm that the quantity matches the order;
b. Label and stamp the outer box;
c. Provide a shipping report.
b. Label and stamp the outer box;
c. Provide a shipping report.
Step 15
OQC Shipping Inspection
Testing Instruments
Calipers, projectors, pin gauges, tooth gauges, outer packaging inspection, etc.
Note
Verify if the measuring device is still within its calibration window and whether it meets both customer and SIP requirements.
Frequently Asked Questions (FAQ)
What aluminum material standard is used in the die casting process?
We use ADC12 aluminum alloy, which meets international standards including US-383, Russia-AJ16, German-AlSi8Cu3, UK-LM2, Italy-4520, and Eu-ENAC-46400.
What quality checks are performed during the IPQC inspection?
IPQC inspection checks dimensions against drawings using three-dimensional measuring systems, projectors, film thickness meters, colorimeters, salt spray testers, hundred-grid tools, and alcohol/pencil tests.
What is the tolerance requirement for the backside shaping processes?
In the initial shaping stage (Step 7), the backside plane must be within 0.15mm. In the final shaping stage (Step 11), the backside plane tolerance must be kept within 0.2mm.
What are the key requirements for the electrophoresis surface treatment?
The color must be uniform and consistent with the sample. The surface must be free from defects such as color variations, dirt, exposed bottom metal, paint buildup, bubbles, touches, and scratches.
How are the products packaged for shipping?
Products are placed securely into a knife card separator layout. The upper layer is then protected with flat cardboard before being boxed to prevent damage and deformation.
How is measuring equipment accuracy ensured?
All testing instruments used during FQC and OQC inspections (such as calipers, projectors, pin gauges, and tooth gauges) are strictly monitored to ensure they are within their valid calibration window.