Why Surface Treatments Essential for Aluminum Squeeze Castings

Imagine you invest in a high-quality aluminum casting part for your automotive project, but find it corroded and worn out in a few months.

It’s frustrating, isn’t it? This is where surface treatments come to the rescue, enhancing the durability and performance of squeeze-cast aluminum parts.

Surface treatments can significantly improve the quality of squeeze castings, by increasing corrosion resistance, enhancing surface finish, improving mechanical properties, and adding decorative appeal. These treatments include mechanical processes, chemical treatments, electroplating, and coatings.

To get high-quality squeeze casting parts goes beyond just the casting process.

While precise mould design and excellent casting techniques are crucial, the final quality of the product can be greatly influenced by the surface treatments applied.

These treatments not only protect the casting but also improve its aesthetic and functional properties, ensuring that the final product meets and exceeds customer expectations.

Common Surface Treatment Methods

Mechanical Treatment

Polishing

Polishing is to use of abrasive materials to make the surface of aluminum parts smoother.

It can remove minor imperfections and make the casting shiny and reflective.

It’s often used in the decorative applications, where the appearance is very important.

polishing

Grinding

Grinding uses a rotating abrasive wheel to remove the material from the surface of the casting.

It is very effective to get a precise surface finish and is often used to prepare the part for further treatments.

grinding

Sandblasting

Sandblasting is a process to propel the fine abrasive particles at high speed onto the surface of the casting.

It can clean the surface and give it a uniform and matte appearance and is often used to prepare the surface for painting or coating.

sandblasting

Shot Blasting

Shot blasting is to bombard the surface of the casting with the small steel balls.

It can clean the surface and induce compressive stresses that can improve fatigue strength.

shot blasting

Chemical Treatment

Pickling

Pickling is to use the acid solutions to remove the oxides and other contaminants from the surface of the aluminum.

It is very important to prepare the surface for the following treatments, such as plating or painting.

pickling

Phosphating

Phosphating is to make a layer of insoluble phosphate crystals on the surface.

This layer can be used as a base for further coatings and can improve adhesion and corrosion resistance.

phosphating

Anodizing

Anodizing is an electrochemical process to thicken the natural oxide layer on aluminum parts.

It can improve corrosion resistance and surface hardness and allows for the application of various colors.

anodizing

Electroplating

Zinc Plating

Zinc plating is to deposit a thin layer of zinc onto the surface of the aluminum.

It can provide excellent corrosion resistance and is often used in automotive and industrial applications.

zinc plating

Chrome Plating

Chrome plating is to apply a layer of chromium onto the surface.

It can give a hard and wear-resistant finish with a high aesthetic appeal and is often used for decorative purposes.

chrome plating

Coating

Powder Coating

Powder coating is to apply the dry powder onto the surface and then cure it under heat.

It can create a tough and durable finish that is resistant to corrosion and chipping.

powder coating

Spray Painting

Spray painting is to apply the liquid paint onto the surface of the casting.

It is very flexible and allows for various colors and finishes.

spray painting

Electrophoretic Coating

Electrophoretic coating, or e-coating, uses an electric field to deposit the paint onto the surface.

It can make even coverage and excellent adhesion and is often used for complex shapes.

electrophoretic coating

Pros and Cons

Mechanical Treatment

Polishing

Pros: polishing provides a high-gloss finish and removes imperfections.

Cons: It is labor-intensive and costly, especially for large parts.

Grinding

Pros: grinding achieves precise surface finishes and prepares parts for further treatments.

Cons: it may introduce stress and generate heat, requiring skilled operators.

Sandblasting

Pros: sandblasting cleans surfaces and creates a uniform finish efficiently.

Cons: it can damage delicate parts and requires proper ventilation and safety measures.

Shot Blasting

Pros: shot blasting improves fatigue strength and provides a uniform texture.

Cons: it can deform thin parts and generate noise, requiring proper safety measures.

Chemical Treatment

Pickling

Pros: pickling effectively takes away oxides and prepares surfaces for further treatments.

Cons: it involves hazardous chemicals and requires proper waste disposal.

Phosphating

Pros: phosphating enhances coating adhesion and corrosion resistance.

Cons: it requires precise process control and involves handling chemicals.

Anodizing

Pros: anodizing enhances corrosion resistance and enables decorative finishes.

Cons: it can be costly and requires precise control to guarantee quality.

Electroplating

Zinc Plating

Pros: zinc plating offers excellent corrosion resistance and is cost-effective.

Cons: it may cause hydrogen embrittlement and requires passivation for better protection.

Chrome Plating

Pros: chrome plating provides a hard, wear-resistant finish with high aesthetic appeal.

Cons: it involves toxic chemicals and can be expensive.

Coating

Powder Coating

Pros: powder coating makes a durable, corrosion-resistant finish with minimal waste.

Cons: it requires curing ovens and may not be suitable for heat-sensitive materials.

Spray Painting

Pros: spray painting is versatile and easy to apply with various colors and finishes.

Cons: it involves VOCs and is less durable than other methods.

Electrophoretic Coating

Pros: electrophoretic coating guarantees even coverage and good corrosion resistance.

Cons: it requires precise control and specialized equipment, making it costly.

The Necessity of Surface Treatments

Corrosion Resistance

Aluminum alloys are not easy to rust, but they can still corrode in some cases.

Surface treatments such as anodizing or coating can improve the corrosion resistance of aluminum squeeze castings.

This is very important, especially in industries like aerospace and marine because their components are often used in harsh environments.

Durability

Treatments such as shot blasting and electrophoretic coating increase the durability of squeeze castings under harsh environments.

These processes increase surface hardness and fatigue resistance, ensuring that parts can withstand heavy use and harsh conditions.

Surface Finish

A smooth and defect-free surface is very important for both appearance and function.

Polishing and grinding can remove surface defects and give the parts a good appearance.

Meanwhile, they can also reduce the friction and wear in the mechanical applications.

Surface Hardness

Processes like chrome plating and anodizing can greatly improve the surface hardness of aluminum parts.

This is especially important for components that are subject to high wear and tear, such as automotive parts and industrial machinery.

Mechanical Properties

Surface treatments can greatly improve the mechanical properties of squeeze-cast aluminum parts.

For example, shot blasting or anodizing can increase the surface hardness and fatigue resistance, making the components can be more durable and reliable in demanding applications.

Decorative Appeal

For the parts that are visible and need a polished look, surface treatments can make them more attractive.

For example, for consumer electronics and automotive trim, surface treatments can not only protect the surface but also make the parts colored and textured, giving designers greater flexibility in product aesthetics.

Applications

Automotive

In the automotive industry, aluminum squeeze castings with surface treatments are widely used in engine components, transmission parts, and suspension systems.

Anodizing and powder coating are the most common treatments to improve corrosion resistance and durability.

Aerospace

In the aerospace industry, surface treatments like anodizing and electrophoretic coating are very important for the components exposed to harsh environments.

These treatments can guarantee the high performance and long service life of critical parts.

Machinery

Surface-treated squeeze castings are widely applied in machinery for gears, housings, and structural components.

Treatments such as shot blasting and zinc plating can improve the mechanical properties and corrosion resistance of these parts.

Fluid Control

In the fluid control industry, aluminum squeeze castings are commonly used for valves, pumps, and fittings.

Surface treatments such as anodizing and powder coating can offer the necessary protection against corrosion and wear.

Marine

In the marine industry, surface treatments are very important for the parts exposed to salt water.

Anodizing and powder coating can offer excellent corrosion resistance for components such as propellers and housings.

Electronics

Surface-treated aluminum parts are widely used in electronics for housings and heat sinks.

Anodizing is a commonly used treatment to protect the components and give them a nice appearance, making the parts durable and visually attractive.

Construction

Surface-treated aluminum squeeze castings are widely used in the construction industry for structural components and decorative elements.

Anodizing and powder coating can enhance the durability and aesthetic appearance of these parts.

Cases by CEX Casting

At CEX Casting, we have rich experience in manufacturing high-quality surface-treated aluminum squeeze castings.

Our advanced facilities and patented technologies can guarantee that each part complies with the highest standards of quality and performance.

From automotive components to delicate electronic housings, our surface treatments provide the necessary protection and enhancement for a wide range of applications.

The following images are surface-treated squeeze castings we have developed:

surface treated squeeze casting parts

Conclusion

Surface treatments are critical for improving the quality and durability of aluminum squeeze castings.

They can bring a lot of benefits, such as better corrosion resistance, higher mechanical properties, and superior surface finishes.

From polishing and anodizing to powder coating and electroplating, each method comes with its purpose, so that the castings can meet the strict requirements of different industries.

As a professional supplier, we offer comprehensive surface treatment services to provide excellent aluminum components, that not only meet but exceed customer expectations.

Choosing the right surface treatment can greatly extend the service life and improve the performance of castings, making it a very important step in the whole production process.

Contact us today for more detailed info about our surface treatment services and cases.

Update cookies preferences
Scroll to Top