In the process of aluminum product processing, it is very important to ensure product quality, and defect detection and prevention are the key links.
First of all, appearance defects are a common problem. Surface damage such as scratches and abrasions may be caused by improper operation or material handling during processing. To prevent such defects, strict operating procedures need to be established in the processing workshop to standardize protective measures during material flow, such as using special protective pads and clamps to avoid contact between aluminum products and sharp or rough objects. At the same time, regularly check the surface finish of the processing equipment to ensure that the tools, molds, etc. are not damaged or burred to avoid damage to the aluminum products during processing.
Porosity and shrinkage are defects that are easy to occur in the casting of aluminum products. This is usually related to the pouring process and solidification process of the aluminum liquid. During pouring, the pouring speed, temperature and pressure should be reasonably controlled to ensure that the aluminum liquid fills the mold cavity smoothly and avoids the entrainment of gas. Optimize the design of the cooling system of the mold so that the aluminum liquid can solidify evenly and reduce the generation of shrinkage cavities. Using methods such as vacuum pouring or adding degassing agents can also effectively reduce the gas content in the aluminum liquid and reduce the probability of porosity defects.
Dimensional deviation is also one of the common defects. The reasons may include precision errors of processing equipment, tool wear, and improper process parameter settings. To ensure dimensional accuracy, the equipment should be accurately calibrated before processing, and worn tools should be checked and replaced regularly. When programming, carefully check the process parameters, such as cutting speed, feed rate, etc., and optimize and adjust them in combination with the material properties of aluminum products. At the same time, increase the frequency of dimensional inspection during the process, such as using high-precision inspection equipment such as three-coordinate measuring machines to promptly detect and correct dimensional deviations.
Crack defects cannot be ignored in aluminum product processing. This may be due to excessive stress on aluminum products during processing, such as excessive deformation during cold processing or improper heat treatment leading to internal stress concentration. To prevent the occurrence of cracks, it is necessary to reasonably design the processing route, control the degree of deformation during cold processing, and add intermediate annealing processes when necessary to eliminate internal stress. For the heat treatment process, it is necessary to strictly follow the process specifications to control the heating speed, holding time and cooling rate.
Inclusion defects may be caused by impurities in the raw materials or foreign matter mixed in during the processing. Therefore, it is necessary to strictly control the quality of raw materials and inspect the raw materials such as aluminum ingots entering the factory to ensure that their purity and impurity content meet the requirements. In the processing workshop, keep the environment clean to prevent foreign matter from mixing into the aluminum liquid or processing area.
In terms of detection, in addition to traditional manual visual inspection, non-destructive testing technologies such as ultrasonic testing and radiographic testing can also be used to detect internal defects of aluminum products, so as to find problems in time and take corresponding remedial measures.
Through the comprehensive application of the above series of defect detection and prevention methods, the processing quality of aluminum products can be effectively improved, the scrap rate can be reduced, and the economic benefits and market competitiveness of enterprises can be improved.
