The working principle of aluminum alloy processing mainly includes the following main steps:
Raw material preparation: Aluminum alloy raw materials usually use aluminum alloy ingots or recycled aluminum materials. The formula of aluminum alloy can be adjusted as needed. Common alloys include aluminum silicon alloy (such as A356) and aluminum copper alloy (such as 2024).
Melting aluminum: The aluminum alloy raw materials are placed in a furnace and heated to a molten state, usually between 660°C and 750°C (the melting point of aluminum is 660.3°C). The type of furnace can be an arc furnace, an induction furnace, etc. During the melting process, impurities and oxides floating on the surface of the aluminum liquid need to be removed to ensure the purity of the aluminum liquid.
Mold preparation: Select a suitable mold according to the complexity of the part. Common mold types include sand molds, metal molds, shell molds, etc. Mold design needs to consider factors such as the fluidity of the aluminum liquid, the cooling rate, and the shrinkage of the parts.
Casting: The molten aluminum liquid is injected into the mold through the pouring system. The pouring method can be gravity casting, low-pressure casting or high-pressure casting. The pouring process needs to control the flow rate and pressure to ensure that the aluminum liquid can completely fill the mold and avoid pores and inclusions.
Cooling and solidification: The aluminum liquid cools and solidifies in the mold to form a cast aluminum part. The cooling rate affects the structure and performance of the casting. The cooling method can be natural cooling or forced cooling.
Demolding and finishing: The cooled cast aluminum part is removed from the mold. The demoulding process requires care to avoid damaging the casting. Castings usually need to remove excess aluminum, gates, risers, etc., and perform surface treatment and size adjustment.
Inspection and post-processing: The cast aluminum parts are inspected, including dimensional accuracy, surface defects, mechanical properties, etc., to ensure that they meet the design standards. As needed, cast aluminum parts may require post-processing processes such as heat treatment, spraying, and electroplating to improve performance and appearance.