As an indispensable metal forming technology in modern manufacturing, aluminum die casting is widely used in the fields of automobile, electronics, aerospace, etc. with its high efficiency, high precision and high consistency. This process is essentially a manufacturing method in which molten aluminum is injected into a precision mold cavity under high pressure, and the desired shape parts are formed after rapid cooling and solidification. Compared with traditional gravity casting, die casting has obvious technical advantages, including faster production cycle, higher dimensional accuracy and better surface quality.
In this process, the quality control of molten aluminum is directly related to the performance and yield of the final product. As an important link in the purification of aluminum liquid, the application of fiberglass filters plays a key role in improving the quality of castings.
This article will deeply explore the characteristics of aluminum die casting process, the technical characteristics of fiberglass filters and their application value in actual production.
Overview of aluminum die casting process and technical challenges
The typical aluminum die casting process includes: aluminum ingot smelting, alloying treatment, melt refining, high-pressure injection molding, cooling and demolding. Compared with gravity casting, die casting has the characteristics of high production efficiency, good dimensional accuracy and excellent surface quality, and is particularly suitable for the production of large quantities of complex-shaped parts.
However, the aluminum die casting process also faces many technical challenges. Under high temperature conditions, aluminum liquid easily reacts with oxygen in the air to generate oxide inclusions such as Al₂O₃. At the same time, the high-speed filling characteristics of the die casting process make it easier for inclusions to be drawn into the casting, forming sources of defects such as pores and shrinkage. According to statistics, about 70% of the scrap in aluminum die castings is related to the purity of the melt. These defects not only affect the appearance of the product, but also reduce the mechanical properties and service life.
Technical Features of Fiberglass Mesh Filters
As an effective solution to the problem of aluminum liquid purity, fiberglass filter has the following significant technical characteristics:
- Excellent temperature resistance: Using a special alkali-free or low-alkali aluminum borosilicate glass component, it can maintain structural stability at a molten aluminum temperature of 700-800℃. After special heat treatment, the thermal expansion coefficient of high-quality glass fiber filters is well matched with aluminum liquid to avoid rupture caused by sudden temperature changes.
- Mesh filter structure: By precisely controlling the fiber diameter and weaving density, a network structure is formed, and large-sized inclusions are intercepted by the surface layer.
- Good chemical stability: It exhibits excellent corrosion resistance in various aluminum alloy melts, can effectively resist aluminum water erosion, and meet the needs of aluminum alloy die casting for automobiles.
- Controllable physical properties: By adjusting the fiber diameter, weaving density and surface treatment process, a product series with different filtration accuracy and flux can be obtained to meet the diverse needs from ordinary commercial parts to high-end structural parts.
- Customizable shape: The fiber mesh can be easily cut into various sizes with its unique material, and can also be customized into various cap-shaped shapes to adapt to different casting environments and automation equipment.
Application Practice of Fiberglass Filters for Aluminum Die Casting Process
On the aluminum die casting production line, the rational use of fiberglass filters is crucial to ensure product quality. It is mainly used in the following key links:
- Smelting and transfer link: A filter device is set in the aluminum liquid transfer channel between the melting furnace and the holding furnace or the injection chamber to effectively remove oxide inclusions and flux residues generated during the smelting process. The filtration in this link has a significant impact on the stability of the subsequent process.
- Pouring system integration: The filter is integrated into the casting system of the mold to protect the cavity from contamination to the greatest extent. This method is particularly suitable for precision die-casting parts with high quality requirements, such as automobile engine parts.
- Process parameter matching: The filtration effect is closely related to the temperature of the aluminum liquid. Practice has proved that controlling the aluminum liquid temperature within the range of 720-760℃ can not only ensure good fluidity, but also extend the service life of the filter. At the same time, the reasonable selection of the filter area also directly affects the filtration efficiency and replacement frequency.
In actual applications, the performance of the glass fiber filter is significantly better than other traditional purification methods. Compared with flux treatment, mechanical filtration does not introduce new pollution sources; compared with the static method, the filtration treatment is more efficient and adapts to the needs of continuous production. Especially in mass production, the economic and convenient advantages of glass fiber filters are more prominent.
Conclusion
As a key functional material in the aluminum die-casting process, the technical level and application level of glass fiber filters directly affect the quality and production cost of the final product. Choosing a suitable filtration solution requires comprehensive consideration of factors such as product characteristics, quality requirements and production conditions.
SEFU’s technological innovation and product advantages
As a professional casting material supplier, SEFU has been deeply involved in the field of aluminum die-casting filtration for many years and has accumulated rich technical experience. SEFU’s technical service team can provide professional filtration solution design support to help customers choose the most suitable filtration products and process parameters according to specific product characteristics, quality requirements and production conditions.
SEFU will continue to increase R&D investment, cooperate with universities and research institutions, and promote the innovative development of filtration technology. We believe that through the joint efforts of material suppliers and die-casting companies, the quality and performance of aluminum die-casting products will continue to improve, creating greater value for terminal application fields.
We sincerely invite colleagues in the industry to have in-depth exchanges and cooperation to jointly explore the latest developments and application practices of aluminum die-casting filtration technology. Through continuous technological innovation and process optimization, we will continuously improve the quality and competitiveness of aluminum die-casting products and drive the entire industry to a higher level.