Cosa comporta un'efficace post-elaborazione della pressofusione?

In die casting production—whether for new energy vehicle motor housings or 5G base station cooling modules—post-processing of die casting is the final step that turns raw castings into high-performance, market-ready parts. It fixes casting defects, optimizes surface quality, and ensures parts meet design standards. Questo articolo analizza i suoi obiettivi principali, key processes, quality control methods, defect solutions, and cost-saving tips, helping you build a efficient post-processing workflow.

1. What Are the Core Goals and Principles of Die Casting Post-Processing?

Post-processing isn’t random—it follows clear goals and principles to avoid rework and ensure consistency.

1.1 Core Goals

The work focuses on four key objectives, tailored to part functions:

• Eliminate Casting Defects: Fix issues like shrinkage, pores, and flash left from casting.
• Optimize Surface Quality: Achieve smooth finishes or protective coatings for appearance and durability.
• Adjust Mechanical Properties: Boost strength, durezza, or creep resistance through heat treatment.
• Meet Design Accuracy: Ensure dimensions, planarità, and other specs match engineering requirements.

1.2 Guiding Principles

To prevent secondary damage and save time, two rules are non-negotiable:

• “Rough First, Then Fine”: Do heavy-duty work (like cutting sprues) Primo, then precision tasks (come macinare). This avoids scratching finished surfaces.
• “Inside First, Then Outside”: Machine internal features (like holes) before external ones. Internal machining is more likely to cause minor deformation, which can be corrected when finishing the exterior.

2. What Are the Key Processes in Die Casting Post-Processing?

Post-processing has five core steps, each with specific techniques and parameters. Below is a detailed breakdown for industrial use:

2.1 Sprue, Riser, and Flash Removal

This step cleans up excess material from casting. The method depends on production volume and precision needs:

Nota: Utilizzo taglio a freddo for aluminum-magnesium alloys to avoid heat-affected zones that weaken the part.

2.2 Surface Treatment Combinations

Surface treatment improves appearance, Resistenza alla corrosione, e funzionalità. Choose based on material and part use:

2.3 Lavorazione di precisione

This step refines dimensions and shapes. Success depends on clamping strategies and parameter optimization:

2.3.1 Clamping Strategies for Different Part Types

2.3.2 Optimized Machining Parameters

2.4 Heat Treatment Strengthening

Heat treatment boosts mechanical properties. Use material-specific schemes:

Note critiche: Magnesium alloys need inert gas to avoid oxidation; Zinc alloys must not exceed eutectic temperature (causes melting).

2.5 Special Processing

For residual stress relief and sealing protection:

3. How to Control Quality in Die Casting Post-Processing?

Quality control ensures parts meet standards. Use the right tools and tests:

4. How to Fix Common Post-Processing Defects?

Defects like shrinkage or pores can be resolved with targeted solutions:

5. How to Control Costs and Cycles in Post-Processing?

Post-processing accounts for a large portion of total costs—optimize to save money and time:

6. Yigu Technology’s Perspective on Post-Processing of Die Casting

Alla tecnologia Yigu, vediamo post-processing of die casting as the “value-adding bridge” between raw castings and high-quality parts. I nostri dati mostrano 70% of part failures stem from rushed or mismatched post-processing—e.g., using heat treatment on porous aluminum parts causes cracking.

We recommend a “process-material matching” approach: For ADC12 aluminum alloy motor housings, we pair T6 heat treatment with precision boring to hit flatness <0.05mm/100 mm; Per maniglie medicali in lega di zinco Zamak5, utilizziamo la nanocromatura + incisione laser per soddisfare gli standard ISO 10993 standard di biocompatibilità. Integrando l'automazione (come l'ispezione dell'IA) e schemi specifici del materiale, aiutiamo i clienti a ridurre i costi 25% migliorando al contempo l'affidabilità delle parti.

7. Domande frequenti: Common Questions About Post-Processing of Die Casting

Q1: Can all die casting materials use the same surface treatment?

NO. Per esempio, l'anodizzazione funziona solo su leghe di alluminio (forma uno strato di ossido), mentre l'ossidazione al microarco è migliore per le leghe Al/Mg/Ti. Le leghe di zinco sono spesso galvanizzate per la decorazione, ma la verniciatura a polvere funziona per la maggior parte dei metalli: abbina sempre il trattamento al materiale e alla funzione della parte.

Q2: Why is quench transfer time critical for aluminum alloy heat treatment?

Leghe di alluminio (come l'A380) necessitano di un raffreddamento rapido dopo il trattamento con la soluzione per intrappolare gli elementi di rinforzo. Se il tempo di trasferimento supera 30 Secondi, gli elementi precipitano presto, riducendo la resistenza alla trazione fino a 20%. Utilizziamo sistemi di tempra automatizzati per mantenere i tempi di trasferimento <25 Secondi.

Q3: How to reduce deformation in thin-walled die casting post-processing?

Utilizza tre metodi: 1) Morsetto con ventose a vuoto + cuscinetti a nido d'ape per distribuire la pressione; 2) Utilizzare velocità di taglio basse (50-80M/min per alluminio) per ridurre al minimo la forza; 3) Aggiungere una fase di trattamento criogenico (-196°C per 24 ore) per rilasciare lo stress residuo prima della lavorazione di precisione. Questi riducono la deformazione 60%.