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How to avoid pores in electric control system die castings
In the design and manufacture of modern electronic control systems, electric control system die castings, as one of the core components, play a vital role. Especially in applications with high electrical performance requirements and strict dimensional accuracy, the quality of die castings directly affects the stability and service life of the entire electronic control system. Porosity is one of the common defects in die castings. It not only affects the mechanical properties of die castings, but may also cause electrical performance degradation and even cause system failures. Therefore, how to avoid pores in electric control system die castings is an urgent problem to be solved.
Analysis of the causes of pores
In the die-casting production process of electronic control systems, pores are mainly caused by the following reasons:
Air entrainment: During the process of liquid metal being injected into the mold, air is entrained into the mold cavity. As it cools and solidifies, the air cannot escape completely, and eventually pores are formed.
Pouring speed is too fast or too slow: Improper pouring speed may cause too much air to be brought in when the liquid metal flows quickly, or flow too slowly, causing the gas to fail to be discharged in time in the molten metal.
Improper mold design: The exhaust channel design of the mold is unreasonable, and the gas cannot be effectively removed, resulting in gas being trapped inside the die casting.
The gas content of the aluminum alloy itself is too high: the aluminum alloy may contain moisture or impurities, which will release gas at high temperatures to form pores.
Improper mold temperature control: Overcooling or overheating the mold will affect the fluidity and solidification rate of the metal, resulting in the formation of pores.
How to avoid the formation of pores
1. Optimize the pouring process
Ningbo Jinyao Machinery Co., Ltd. continuously optimizes the pouring process in the process of producing high-precision die castings to ensure that the liquid metal can smoothly and evenly fill the mold cavity when injected into the mold. Especially in the high-pressure casting process, the use of reasonable pouring speed and pressure can effectively prevent air entrainment, while avoiding the splashing and splashing of the molten metal, thereby reducing the formation of pores.
In addition, reasonable control of pouring temperature and pressure is an important means to avoid pores. Overcooling or overheating of the molten metal will lead to poor metal fluidity and increase the risk of gas entrainment. Therefore, Ningbo Jinyao's production line strictly controls the pouring temperature of aluminum alloy to ensure good metal fluidity and avoid the formation of pores.
2. High-pressure vacuum technology
Ningbo Jinyao Machinery Co., Ltd. applies advanced high-pressure vacuum technology, which has a significant effect on eliminating pores. In the die-casting process, the vacuum extraction method can effectively reduce the air content inside the mold, and help the metal liquid to flow quickly through the vacuum environment, thereby reducing the gas encapsulation. By optimizing the vacuum technology, not only can the generation of pores be avoided, but also the density and strength of the casting can be improved.
3. Accurate mold design and exhaust system
Mold design is a key factor affecting the generation of pores. Reasonable mold design can ensure smooth flow of molten metal and can efficiently discharge the gas in the mold cavity. Ningbo Jinyao Machinery Co., Ltd. is committed to the design and manufacture of precision molds, using high-pressure point cooling technology and mold exhaust system optimization to ensure that when the aluminum alloy liquid metal is injected, the gas inside the mold can be quickly discharged, thereby avoiding the formation of pores.
Specifically, the exhaust channel of the mold must be sufficiently unobstructed, and the position and number of the exhaust holes must be precisely designed according to the shape and thickness of the casting to prevent the gas from being retained at a certain position during the flow process and forming pores.
4. Use high-quality aluminum alloy materials
The material of aluminum alloy directly affects the quality of die-casting parts. The aluminum alloy materials used by Ningbo Jinyao Machinery Co., Ltd. have low gas content and better fluidity after strict screening, which can reduce the release of gas during the die-casting process. In order to ensure the quality of aluminum alloy, the company also uses advanced smelting technology to reduce impurities in aluminum alloy, improve the purity of metal, and avoid the generation of pores from the source.
5. High-precision temperature control system
The influence of temperature control system on the quality of die-casting parts cannot be ignored. Too low or too high mold temperature will affect the solidification speed of the casting and may cause pores. Ningbo Jinyao Machinery Co., Ltd. achieves fine temperature control by adopting a high-precision mold temperature control system. Especially in the high-pressure casting process, ensure that the temperature of the mold is uniform, the molten metal can flow evenly and solidify in time, and avoid the appearance of pores.
6. Optimization of heat treatment process
After casting, in order to further reduce the impact of pores on the performance of castings, Ningbo Jinyao Machinery Co., Ltd. also conducts strict heat treatment process. Heat treatment can eliminate the residual stress inside the casting and further reduce the presence of pores. The company uses advanced heat treatment furnaces to ensure that each casting can achieve the best performance requirements during the heat treatment process.
What are the special requirements for heat dissipation design of electric control system die castings?
Electronic control systems play a core role in modern electronic equipment and mechanical engineering, especially in terms of electrical performance, thermal management and stability. For electric control system die castings, heat dissipation design is a key link in their design and manufacturing process. Since die castings are usually used to carry key components of electronic control systems, good heat dissipation performance can not only improve their working efficiency, but also extend the service life of the system and prevent electrical failures caused by overheating.
Ningbo Jinyao Machinery Co., Ltd., as a professional manufacturer of aluminum alloy precision die castings and high-pressure casting molds, has rich experience and technical accumulation in this field. Through high-precision die-casting process and heat treatment technology, the company can not only produce high-quality electronic control system die-castings that meet customer needs, but also effectively solve its heat dissipation problems. This article will combine Ningbo Jinyao's practice to elaborate on the heat dissipation design requirements of electronic control system die-castings.
1. Thermal conductivity of aluminum alloy materials
The heat dissipation design of electronic control system die-castings must first consider the selection of aluminum alloy materials. Aluminum alloys are widely used in electronic equipment and electronic control systems due to their excellent thermal conductivity and lightweight characteristics. Compared with other metal materials, aluminum alloys have higher thermal conductivity and can effectively transfer heat from the electronic control system to the external environment.
The high-quality aluminum alloy materials used by Ningbo Jinyao Machinery Co., Ltd. are carefully selected to ensure that they have ideal thermal conductivity. Through advanced die-casting technologies such as vacuum exhaust, pinhole extrusion and other processes, the density of aluminum alloys is further improved to ensure that heat can be efficiently transferred from the inside of the electronic control system to the outside.
2. Accurate mold design and heat dissipation channel
The heat dissipation design of electronic control system die-castings not only depends on the material itself, but is also closely related to mold design. Reasonable mold design can improve the heat exchange efficiency by adding heat dissipation channels or changing the structure of the mold.
Ningbo Jinyao Machinery Co., Ltd. is well aware of the importance of heat dissipation channel design for improving the heat dissipation capacity of electronic control system die castings. In the mold design process, the company uses high-pressure point cooling technology to ensure that when the aluminum alloy is injected in liquid form, the structural characteristics of the mold can be effectively used to guide the release of heat. At the same time, in the design of the casting, the company further improves the heat dissipation efficiency by adding heat dissipation fins, heat dissipation slots or micro-channels to ensure that the thermal management of the die casting reaches the optimal state.
In addition, the exhaust design of the mold is equally important. Since the presence of pores and gas will cause heat accumulation, Ningbo Jinyao will pay special attention to the smooth flow of the exhaust channel when designing the mold to avoid gas blockage and ensure that the heat can be dissipated smoothly.
3. Optimized high-pressure casting process
High-pressure casting is a process commonly used to manufacture high-precision die castings, and Ningbo Jinyao has rich experience in this field. By adopting high-pressure casting technology, liquid metal can be quickly filled in the mold, ensuring the density of the casting and reducing the generation of pores and internal defects. This process not only improves the strength of aluminum alloy, but also optimizes its thermal conductivity, thereby improving the heat dissipation effect.
In order to further improve the thermal management performance of the casting, Ningbo Jinyao also uses high-pressure point cooling technology, which can achieve precise temperature control during the casting process, reduce thermal stress and deformation, and help more uniform heat dissipation.
4. Heat treatment process and heat dissipation performance optimization
Although aluminum alloy itself has good thermal conductivity, the heat dissipation performance of the casting can be further optimized through appropriate heat treatment process. Ningbo Jinyao provides customized heat treatment services for all electronic control system die castings. Through heat treatment process, the microstructure of aluminum alloy is enhanced, so that it can better conduct heat during operation and maintain its good heat dissipation performance.
Specifically, the heat treatment methods used by Ningbo Jinyao include aging hardening and solution treatment, which can make aluminum alloy work stably in high temperature environment and ensure that the heat dissipation capacity is not affected during the operation of the electronic control system.
5. Appearance design and heat dissipation performance
The appearance design of die castings has a direct impact on the improvement of heat dissipation performance. Ningbo Jinyao focuses on the innovative design of die-casting parts, especially for parts such as housings and brackets used in electronic control systems. To improve heat dissipation efficiency, the company's castings usually have heat dissipation fins, heat dissipation slots and curved shape structures, which can increase the contact area with the air and thus increase the heat dissipation rate.
The design of heat dissipation fins can effectively increase the heat dissipation area and promote the rapid release of heat. The heat dissipation slots and curved shape structures help improve airflow and heat convection, thereby further optimizing the heat dissipation effect.
6. Integration of the overall heat dissipation system
The heat dissipation design of the electronic control system is not just a single die-casting heat dissipation problem, it needs to be effectively integrated with the heat dissipation design of the entire system. In this regard, Ningbo Jinyao, with its rich manufacturing experience, is able to provide customers with customized solutions. The company can design die-castings that match the heat dissipation solutions of other parts of the electronic control system according to the specific needs of customers, thereby achieving thermal management of the entire system.
For example, in electronic control systems, die-castings often work in conjunction with other heat dissipation components (such as radiators, fans, etc.). Ningbo Jinyao works closely with customers to ensure that its die-castings can form an effective heat dissipation system with these components, avoiding heat accumulation in one part and ensuring that the entire electronic control system can maintain a stable temperature even when working at high loads.