Aluminum Casting Processes Quality Control
We strictly adhere to the quality control requirements of the ISO 9001 and IATF 16949 systems for aluminum casting processes.
From raw materials to finished products, from initial samples to large-scale production, every step undergoes rigorous quality testing.
Quality Inspection of Aluminum Castings
For each batch of die casting products, we conduct mould inspection, sample inspection, and batch product inspection according to specified procedures.
| Inspection Contents | Inspection Methods/Instruments |
| Mould Dimensions | Micrometer, Vernier Caliper, Full Range Pin Gauge/Gauge |
| Appearance | Visual Inspection (Naked Eye, Magnifying Glass), Color Inspection |
| Material Composition | Chemical Analysis, Spectral Analysis |
| Dimensions and Tolerances | Coordinate Measuring Machine (CMM), Micrometer, Vernier Caliper, Full Range Pin Gauge/Gauge |
| Mechanical Properties (Strength, Hardness, Density) | Tensile Testing Machine, Hardness Tester, Density Tester |
| Internal Structure (Porosity) | X-Ray, Ultrasonic Testing, Destructive Testing, Metallographic Examination |
| Other Requirements Control (Pressure Resistance, Sealing Performance) | Sealed Pressure Resistance Test |
Control of the Production Process
Each production step follows specified operating procedures.
For the die casting process, we have established a die casting process card. We set the parameters of the die casting machine according to the requirements of the process card, and continuously monitor and record each parameter.
If any parameter deviates, an alarm will be triggered to take corrective action. This ensures the accuracy of our die casting process, thereby ensuring the qualification rate of die casting products.
Our Quality Control Instruments
- Coordinate Measuring Machine (CMM) with a measurement range of 800×1200×600 (mm) and a Maximum Permissible Error (MPE) of 3.0μm
- Tensile Strength Testing Machine
- Hardness Tester
- Profile Projector
- Granite Measurement Workbenches, 1200×1000 (mm) / 1000×750 (mm)
- Digital Height Gauge, 0-600 (mm)
- Full Range Vernier Caliper, 0-100-150-200-300-600-1000 (mm)
- External/Internal Micrometers, 0-25-75-100-125-150 (mm) / 12-20-50-100 (mm)
- Full Range Pin Gauge/Gauge, 0.5-12 (mm) / 1.0-100 (mm), with a spacing of 0.01mm
How Do We Check the Quality of Aluminum Die Castings
1. Before starting casting, use the spectrometer to detect the composition of the raw materials.
2. After removing the casting blank from the mold cavity, visually inspect the forming condition and whether there are any major defects on the surface.
3. Using calipers and micrometers to check the dimensions of rough castings.
4. Using the X-ray machine to inspect the internal defects of castings (this step is 100% inspection for automotive parts).
5. Using the fluorescence analysis to inspect surface defects of castings (this step is 100% inspection for automotive parts).
6. Using the tensile testing machine to test the mechanical properties of castings. (If needed, conduct proportional sampling inspection).
7. Using the CMM (coordinate measuring machine) to inspect the full size of castings.
How Do We Check the Quality of Aluminum Squeeze Castings
The inspection of squeeze castings is more complex than that of die castings, especially for mechanical properties and air-tightness requirements:
1. Before starting casting, use the spectrometer to detect the composition of the raw materials.
2. After removing the casting blank from the mold cavity, visually inspect the forming condition and whether there are any major defects on the surface.
3. Using calipers and micrometers to check the dimensions of rough castings.
4. Using the X-ray machine to inspect the internal defects of castings (this step is 100% inspection for automotive parts).
5. Using the tensile testing machine to test the mechanical properties of castings after heat treatment (proportional sampling inspection).
6. Using the fluorescence analysis to inspect surface defects of castings (this step is 100% inspection for automotive parts).
7. Using water immersion testing or helium leakage testing methods to test the airtightness. (this step is 100% inspection for automotive parts with airtight requirements).
8. Using the blasting testing machine to check the blasting pressure. (this step is proportional sampling inspection for automotive parts with requirements).
How to Inspect Porosity of Aluminum Squeeze Castings
To inspect porosity in squeeze castings effectively, combine visual inspection, x-ray radiography, ultrasonic testing, and computed tomography (CT) scanning methods. Start with a detailed visual examination to identify surface defects.
For deeper insights, use X-ray radiography to detect internal voids by penetrating the metal. Ultrasonic Testing (UT) can be employed to assess the integrity of the casting by detecting flaws through sound waves, providing a reliable method for identifying porosities that are not visible on the surface.
Additionally, CT scanning offers a comprehensive 3D view for precise internal structure analysis, critical for applications demanding high accuracy. Click here to learn more.
How to Conduct Leakage Testing for Aluminum Squeeze Castings
Leakage testing for aluminum squeeze castings is carried out with strict inspection procedures to guarantee the integrity and impermeability of the castings. The water immersion testing and helium leakage testing are the main methods used by CEX Casting.
By these means, we can find out the tiniest defects in the castings, which are critical to making sure that the products can perform reliably under various pressures and conditions, especially in applications such as aerospace and automotive industries. Click here to learn more.