Analysis of Die-Cast Alloy and Aluminum Profile Processing Technology

Aluminum profiles are commonly used in applications such as screens and aluminum windows. They are produced using an extrusion molding process, where raw materials like aluminum ingots are melted in a furnace and then extruded through a die using an extrusion machine to form the desired shape. This process can also create profiles with various cross-sectional designs.

The primary properties, including strength, hardness, and wear resistance, comply with the national standard GB6063. The advantages of aluminum profiles include their lightweight nature (density of only 2.8), resistance to rust, rapid design changes, low mold investment, and the ability to achieve longitudinal elongations of over 10 meters. The surface finish of aluminum profiles can be either glossy or matte. The processing technique involves anodizing, with the surface oxidation film thickness reaching 0.12 mm. The wall thickness of aluminum profiles is optimized based on product design requirements. Contrary to popular belief, thicker walls are not necessarily better; the design should meet the structural requirements of the cross-section, with thicknesses ranging from 0.5 mm to 5 mm. The misconception that thicker walls equate to greater hardness is incorrect.

However, aluminum profile processing also has some inherent surface quality defects that are difficult to overcome, such as warping, deformation, black lines, uneven surfaces, and white lines. Skilled designers, along with reasonable mold design and production processes, can minimize these defects. Defect inspection should follow national standards, typically determined by visual inspection from a distance of 40–50 cm.

Aluminum profiles are widely used in furniture, including screen frames, various hanging beams, table legs, decorative strips, handles, wire channels, covers, chair tubes, and more. They offer versatile design possibilities!

Despite their many advantages, aluminum profiles also have some drawbacks:

- Non-anodized aluminum is prone to "rusting," which can degrade its performance.
- The longitudinal strength of aluminum profiles is inferior to that of iron products.
- The wear resistance of the surface oxide layer is not as good as electroplating, making it more susceptible to scratches.
- The cost of aluminum profiles is higher than that of iron products, typically around 3 to 4 times more.

In comparison, the processing methods for die-cast alloys and aluminum profiles differ significantly. Die-cast aluminum uses raw materials such as aluminum ingots (approximately 92% purity) and alloy materials, which are melted in a furnace and then formed using a die-casting machine. Die-cast aluminum products can be designed into various shapes, similar to toys, allowing for versatile connections in multiple directions. Additionally, die-cast aluminum exhibits high hardness and strength and can be mixed with zinc to form zinc-aluminum alloys.

Key Points of Die-Cast Aluminum Molding Process:

1. Die-casting
2. Rough polishing to remove mold residue
3. Fine polishing

On the other hand, the production process of die-cast aluminum requires the creation of a single mold, which is very expensive—more so than molds used in injection molding. Additionally, repairing molds is challenging, and material adjustments are difficult if design errors occur.

Disadvantages of Die-Cast Aluminum:

- Large production quantities are required to keep costs low.
- Polishing is complex, and the production cycle is slow.
- The product cost is approximately 3 to 4 times higher than that of injection-molded parts.
- Screw holes need to be larger (e.g., 4.5 mm in diameter) to ensure stable connection strength.