1. Reasons for Bursting of Aluminum Alloy Shell Die Casting Workpieces
Pores and Shrinkage: During the die-casting process of aluminum alloy shells, if the mold exhaust is not smooth or there is too much gas in the aluminum liquid, it can cause pores or shrinkage inside the product. These pores and shrinkage holes may become areas of stress concentration during subsequent processing, leading to bursting.
Improper heat treatment: Heat treatment is an important part of the aluminum alloy shell die-casting process. If the heat treatment is improper, such as inaccurate temperature control, too fast or too slow cooling speed, it can lead to uneven internal structure of the aluminum alloy shell, generate internal stress, and cause explosion.
Mechanical processing factors: In the process of mechanical processing, if the cutting parameters are not set properly, the tool selection is improper, or the cutting fluid is not used properly, it can cause significant internal stress inside the aluminum alloy shell, leading to product cracking after processing.
Material issue: When the purity of aluminum alloy is not high enough or contains other impurities, it can cause a decrease in the mechanical properties of the material and easily lead to cracking. In addition, when the wall thickness of the aluminum alloy shell is uneven and there are local situations of being too thick or too thin, it is also easy to cause explosions.
External stress: During the die-casting process of aluminum alloy shells, if subjected to external forces such as collision, compression, etc., significant internal stress is generated inside the product, which can cause explosions.
2. Preventive measures
To prevent sudden burst of aluminum alloy shell die-casting parts during processing, the following measures can be taken:
Control porosity and shrinkage: During the die casting process of aluminum alloy casing, it is necessary to ensure smooth mold exhaust and carry out degassing treatment on the aluminum liquid to reduce gas content. In addition, adjusting parameters such as gate speed and mold temperature appropriately can effectively control the generation of porosity and shrinkage.
Optimize heat treatment process: Based on the type of aluminum alloy and the characteristics of die-casting process, develop a reasonable heat treatment process, including heating temperature, holding time, and cooling rate. During the heat treatment process, temperature and time must be strictly controlled to ensure product quality.
Reasonable selection of cutting tools and cutting parameters: In the mechanical processing process, it is necessary to choose cutting tools and cutting parameters reasonably based on the characteristics and processing requirements of aluminum alloys. The parameters such as cutting speed and cutting depth should be moderate to avoid being too large or too small, in order to reduce the generation of internal stress.
Improving material quality: Using high-purity aluminum alloy materials and strictly controlling the content of chemical composition. At the same time, strengthen quality control during smelting and pouring processes to prevent impurities and gases from mixing into the aluminum liquid.
Pay attention to operational safety: During the aluminum alloy shell die-casting process, ensure the safety of operators. Avoid the occurrence of external impact or collision on the product. Reasonably place the workpiece to avoid excessive stacking and collapse.
Strengthen quality inspection: Conduct strict quality inspection on aluminum alloy shell die-casting parts, including appearance, size, and internal organizational structure. Unqualified products should be promptly handled to prevent them from flowing into the next process. At the same time, regularly inspect and evaluate equipment and processes to ensure they are in good working condition.
