{"id":295,"date":"2024-10-21T11:22:24","date_gmt":"2024-10-21T03:22:24","guid":{"rendered":"http:\/\/www.1.com\/?p=274"},"modified":"2025-02-19T18:56:53","modified_gmt":"2025-02-19T10:56:53","slug":"about-detail-60","status":"publish","type":"post","link":"https:\/\/www.hexinmusu.com\/en\/about-detail-60.html","title":{"rendered":"Aluminum alloy processing technology"},"content":{"rendered":"

As the most widely used non-ferrous metal material, aluminum alloy, by virtue of its unique performance advantages, continues to expand its application in the fields of architectural decoration, transportation, aerospace and so on. According to statistics, the variety of global aluminum alloy products has exceeded 700,000, and the reasonable choice of its processing technology and deformation control is directly related to product quality. Based on the author's more than 20 years of experience in the casting industry, this paper systematically analyzes the eight core machining processes and six surface treatment technologies, and deeply analyzes the causes of machining deformation and response strategies.<\/p>\n\n\n\n

\"\"\/<\/figure>\n\n\n\n

! [Schematic diagram of aluminum alloy machining process application scenarios]<\/p>\n\n\n\n

I. Aluminum alloy core performance advantages<\/h2>\n\n\n\n
    \n
  1. Lightweight Advantage<\/strong>Density is only 2.7g\/cm\u00b3, equivalent to 35% of steel, significantly reducing structural weight.<\/li>\n\n\n\n
  2. Excellent molding performance<\/strong>Elongation up to 30% or more, supports extrusion\/stretching and other complex molding processes.<\/li>\n\n\n\n
  3. Outstanding corrosion resistance<\/strong>: Natural oxide film + anodized treatment, corrosion resistance better than ordinary steel<\/li>\n\n\n\n
  4. Intensity adjustable<\/strong>: 600 MPa tensile strength by alloying\/heat treatment<\/li>\n\n\n\n
  5. Proven surface finish<\/strong>: Anodizing process yield exceeds 95% for colorful tinting<\/li>\n\n\n\n
  6. High recycling rate<\/strong>: Energy consumption of recycled aluminum is only 5% of primary aluminum, which is in line with the requirements of sustainable development.<\/li>\n<\/ol>\n\n\n\n

    II. Comparative analysis of the eight core processing techniques<\/h2>\n\n\n\n

    (i) Cold stamping process<\/h3>\n\n\n\n
      \n
    • Process Characteristics<\/strong>: Adopt 200-2000 tons punching machine, accurate control of wall thickness by die clearance (\u00b10.1mm)<\/li>\n\n\n\n
    • Applicable Scenarios<\/strong>: Cylindrical parts\/shaped parts (e.g. automotive ABS valve body)<\/li>\n\n\n\n
    • Economic analysis<\/strong>: Tooling costs reduced by 40%, but labor costs accounted for 25%<\/li>\n<\/ul>\n\n\n\n

      (ii) Stretch molding process<\/h3>\n\n\n\n
        \n
      • technological breakthrough<\/strong>Multi-station continuous molds for 15 successive deformations (e.g. laptop case)<\/li>\n\n\n\n
      • Precision control<\/strong>: Dimensional tolerances up to IT8, surface roughness Ra0.8\u03bcm<\/li>\n\n\n\n
      • return on investment<\/strong>: Mold development cycle of 8-12 weeks, suitable for mass production of more than 100,000 pieces<\/li>\n<\/ul>\n\n\n\n

        (iii) Precision machining<\/h3>\n\n\n\n
          \n
        • Technology Matrix<\/strong>:\n
            \n
          • 5-axis linked machining center: surface accuracy \u00b10.01mm<\/li>\n\n\n\n
          • Slow-feeding wire-cutting: machining accuracy of \u00b10.003mm<\/li>\n\n\n\n
          • Coordinate grinding machine: Hole diameter tolerance control \u00b10.002mm<\/li>\n<\/ul>\n<\/li>\n\n\n\n
          • Innovative applications<\/strong>: Aero-engine impeller machining using mill-turn technology<\/li>\n<\/ul>\n\n\n\n

            (iv) Laser cutting process<\/h3>\n\n\n\n
              \n
            • parameter optimization<\/strong>:\n
                \n
              • Fiber laser: power 6kW, cutting speed 30m\/min<\/li>\n\n\n\n
              • Nitrogen-assisted: incision oxide layer <5\u03bcm<\/li>\n<\/ul>\n<\/li>\n\n\n\n
              • typical case<\/strong>New Energy Vehicle Battery Tray Cutting Yield Increased to 99.2%<\/li>\n<\/ul>\n\n\n\n

                (v) Special casting processes<\/h3>\n\n\n\n
                Process Type<\/th>Dimensional accuracy<\/th>surface roughness<\/th>Minimum wall thickness<\/th>Applicable Scenarios<\/th><\/tr><\/thead>
                pressure casting<\/td>CT6<\/td>Ra3.2<\/td>1.2mm<\/td>Automotive Engine Casing<\/td><\/tr>
                investment casting<\/td>CT4<\/td>Ra1.6<\/td>0.8mm<\/td>Aviation hydraulic components<\/td><\/tr>
                Low-pressure casting<\/td>CT5<\/td>Ra6.3<\/td>2.5mm<\/td>Wheel manufacturing<\/td><\/tr>
                vacuum die casting<\/td>CT5<\/td>Ra2.5<\/td>1.0mm<\/td>5G Base Station Heat Sink<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

                (vi) Powder metallurgy technology<\/h3>\n\n\n\n
                  \n
                • Technological innovations<\/strong>: Metal Injection Molding (MIM) enables fabrication of 0.5mm miniature parts<\/li>\n\n\n\n
                • performance enhancement<\/strong>Relative density up to 98%, tensile strength up to 30%.<\/li>\n\n\n\n
                • Application Expansion<\/strong>: Intelligent wearable device hinge parts volume production exceeded one million pieces level<\/li>\n<\/ul>\n\n\n\n

                  (vii) Injection molding process<\/h3>\n\n\n\n
                    \n
                  • Technical Parameters<\/strong>:\n
                      \n
                    • Feeding fluidity: \u2265150mm\/10s<\/li>\n\n\n\n
                    • Degreasing efficiency: solvent degreasing + thermal degreasing combination process<\/li>\n<\/ul>\n<\/li>\n\n\n\n
                    • Industry Applications<\/strong>: Zero Defect Delivery of Joint Components for Medical Devices<\/li>\n<\/ul>\n\n\n\n

                      (viii) Squeeze casting technology<\/h3>\n\n\n\n
                        \n
                      • Process Advantages<\/strong>Liquid die forging for 99.51 TP3T tissue densities<\/li>\n\n\n\n
                      • parameter control<\/strong>Specific pressure 80-150MPa, holding time 0.5-2s\/mm<\/li>\n\n\n\n
                      • typical case<\/strong>: Military Armor Plate Elastic Resistance Enhancement 40%<\/li>\n<\/ul>\n\n\n\n

                        Three, six surface treatment technology mapping<\/h2>\n\n\n\n
                          \n
                        1. Anodizing technology<\/strong>:\n
                            \n
                          • Hard anodizing: film thickness 50-150\u03bcm, hardness HV400<\/li>\n\n\n\n
                          • Micro-arc oxidation: breakdown voltage 300V, forming a ceramicized surface<\/li>\n\n\n\n
                          • Typical case: UAV shell corrosion resistance life of more than 1000h<\/li>\n<\/ul>\n<\/li>\n\n\n\n
                          • Two-color anodizing process<\/strong>:\n
                              \n
                            • Masking accuracy: \u00b10.05mm<\/li>\n\n\n\n
                            • Color difference control: \u0394E<1.5<\/li>\n\n\n\n
                            • Application examples: high-end cell phone frame two-color gradient effect<\/li>\n<\/ul>\n<\/li>\n\n\n\n
                            • High-gloss cutting technology<\/strong>:\n
                                \n
                              • Spindle speed: 20000-50000rpm<\/li>\n\n\n\n
                              • Tool life: diamond tools can machine 3000 pieces<\/li>\n\n\n\n
                              • Innovative application: 8K TV bezel mirror effect<\/li>\n<\/ul>\n<\/li>\n\n\n\n
                              • Nano Spraying Process<\/strong>:\n
                                  \n
                                • Film thickness: 20-50\u03bcm<\/li>\n\n\n\n
                                • Adhesion Test: Scratch Method Grade 0<\/li>\n\n\n\n
                                • Technological Breakthrough: Successful Development of Self-Repairing Coatings<\/li>\n<\/ul>\n<\/li>\n<\/ol>\n\n\n\n

                                  Four, processing deformation control five strategies<\/h2>\n\n\n\n

                                  Symmetric processing method: deformation reduction 60%<\/p>\n\n\n\n

                                  Residual Stress Control<\/strong>:<\/p>\n\n\n\n

                                  Vibration aging treatment to eliminate internal stresses above 90%<\/p>\n\n\n\n

                                  Optimization of heat treatment process: graded aging temperature control \u00b13\u00b0C<\/p>\n\n\n\n

                                  Optimization of cutting parameters<\/strong>:<\/p>\n\n\n\n

                                  High speed cutting: line speed 300-800m\/min<\/p>\n\n\n\n

                                  Micro lubrication: oil mist volume control at 5-15ml\/h<\/p>\n\n\n\n

                                  Clamping system improvement<\/strong>:<\/p>\n\n\n\n

                                  Flexible fixture repeatability \u00b10.005mm<\/p>\n\n\n\n

                                  Vacuum clamping force distribution uniformity >95%<\/p>\n\n\n\n

                                  Temperature field control<\/strong>:<\/p>\n\n\n\n

                                  Low temperature cutting: -196\u2103 liquid nitrogen cooling<\/p>\n\n\n\n

                                  Online temperature measurement: infrared temperature measurement accuracy \u00b11\u2103.<\/p>\n\n\n\n

                                  Process route optimization<\/strong>:<\/p>\n\n\n\n

                                  Separation of roughing and finishing: margin control at 0.2-0.5mm<\/p>","protected":false},"excerpt":{"rendered":"

                                  As the most widely used non-ferrous metal material, aluminum alloy, by virtue of its unique performance advantages, continues to expand its application in the fields of architectural decoration, transportation, aerospace and so on. According to statistics, the variety of global aluminum alloy products has exceeded 700,000, and the reasonable choice of its processing technology and deformation control is directly related to product quality. Based on the author's more than 20 years of experience in the casting industry, this paper systematically analyzes the eight core machining processes and six surface treatment technologies, and deeply analyzes the causes of machining deformation and response strategies. ! [Aluminum alloy processing technology application scenarios] I. Aluminum alloy core performance advantages II. Comparative analysis of the eight core processing technology (a) cold stamping process (b) tensile molding process (c) precision machining (d) laser cutting process (e) special casting process ...<\/p>","protected":false},"author":1,"featured_media":1936,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":[],"categories":[21],"tags":[89,69],"class_list":["post-295","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-about-news","tag-aluminium-alloy","tag-aluminum-alloy-manufacturing-process"],"_links":{"self":[{"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/posts\/295","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/comments?post=295"}],"version-history":[{"count":0,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/posts\/295\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/media\/1936"}],"wp:attachment":[{"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/media?parent=295"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/categories?post=295"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/tags?post=295"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}