Secondary Processing &
Quality Assurance
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03-60211668
What is Secondary Processing?
Secondary processing, also known as secondary operations or post-processing, refers to additional manufacturing steps or treatments performed on a product or component after its primary manufacturing process is complete. These secondary processes are typically carried out to enhance the product’s functionality, appearance, or performance, or to meet specific customer requirements.
How can we help?
We offer a wide range of die casting secondary process services from assembling to smoothening edges and quality control to finalize high standard products according to our client’s requirements.
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Information and Explanation:
If you have questions about specific secondary processing techniques, their applications, advantages, or limitations, feel free to ask. We provide detailed information and explanations to help you understand different processes and make informed decisions. -
Process Selection:
If you are unsure about which secondary processing methods would be suitable for your products or components, we can offer guidance. By understanding your requirements, materials, and desired outcomes, we can suggest appropriate processes that align with your needs. -
Optimization Suggestions:
If you are seeking ways to improve efficiency, quality, or cost-effectiveness in your secondary processing operations, we can provide optimization suggestions. This may include recommending alternative techniques, process adjustments, or best practices to enhance your overall operations. -
Troubleshooting and Problem Solving:
If you are facing challenges or encountering issues in your secondary processing activities, we can help troubleshoot and identify potential solutions. By discussing the problem, analysing the factors involved, and providing insights, we can assist in finding resolutions.
Our Services
In addition to die casting, we provide a wide range of value-added secondary processing services such as CNC machining, trimming, polishing, buffing, deburring, shot blasting, tumbling, part assembly, surface finishing or coating application. These processes are conducted by our experienced team to finalize the product with high standard quality finishing based on our client’s needs.
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CNC Machining:
A technique that involves the removal of material from a workpiece using various cutting tools and machinery. It is commonly used to achieve precise dimensions, create complex shapes, improve surface finish, or add specific features to a component. -
Trimming:
A process to remove excess material from die cast part using various tools, such as trimming dies and trimming machines. These tools are designed to precisely trim the part to its desired shape and dimensions without damaging or deforming the part. It also serves as a quick method to remove sharp edges, gating & overflow, and to deburr the parting line. -
Polishing & Buffing:
These techniques are used to improve the surface finishing and to enhance the appearance of the die cast part. It is also to remove any surface imperfections, and provide a smooth, glossy or reflective finish. It involves using abrasive materials, such as sandpaper or polishing compounds, to smoothen the surface of the part by using progressively finer abrasives to achieve a high-quality finish. -
Shot Blasting:
A process that involves propelling small metallic or non-metallic particles at high velocity onto the surface of the die cast part to remove any contaminants, scale, burrs or surface irregularities. Additionally, it can also improve the adhesion of subsequent coatings or finishes applied to the part. -
Tumbling:
A process that requires the die cast part to be placed in a rotating barrel and subjecting them to a tumbling action along with abrasive media, compounds or polishing agents. It helps improve the overall appearance, cleanliness and functionality of the part. It can remove sharp edges, burrs and contaminants, resulting in smoother edges. Tumbling can also create a more uniform surface finish, preparing the part for subsequent coatings, painting or assembly process. -
Surface coating:
A process that applies a protective or decorative layer onto the die cast part. This coating enhances the appearance, improves corrosion resistance, provides thermal insulation or imparts specific functional properties to the part. There are various surface coating methods commonly used in aluminium die casting: Powder Coating, Liquid Painting, Anodizing, Chromating, Thermal Spray Coating, Electroplating.
Quality Assurance
We implement rigorous quality control measures to ensure the consistency and reliability of products. With our established Quality Management System through stringent certification of ISO 9001, we strive towards continuous quality improvement and the highest standard levels for our clients.
Our quality assurance includes processes and measures implemented to ensure that the casted aluminium parts meet the required specifications, standards, and customer expectations. It involves various practices throughout the entire manufacturing process, from tooling design & development to mass production and inspection. Here are some key aspects of our quality assurance:
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Design and Engineering:
Quality assurance begins with careful design and engineering of the part and the die casting mould. This includes considering factors such as material selection, part geometry, draft angles, and tolerances to ensure manufacturability and functionality. -
Material Control:
Quality assurance involves proper control and testing of the aluminium alloys used in die casting. This includes verifying material certifications, conducting chemical analysis, and performing mechanical tests to ensure the alloys meet the required specifications. -
Process Control:
Monitoring and controlling the die casting process is crucial for quality assurance. This involves maintaining stable process parameters, such as temperature, pressure, and injection speed, to ensure consistent and defect-free parts. Statistical process control (SPC) techniques are employed to detect and address any process variations. -
Tooling Inspection and Maintenance:
Regular inspection and maintenance of die casting moulds are essential for quality assurance. This includes checking for wear, damage, or misalignment of the mould components. Proper mould storage and maintenance helps ensure consistent part quality and reduces the risk of defects. -
In-process Inspection:
Quality checks are performed during the die casting process and secondary operations process to identify any defects or issues early on. These may include visual inspections, dimensional measurements, and nondestructive testing methods like X-ray or ultrasonic inspection. -
Post-casting Inspection:
Once the parts are casted, comprehensive inspection and testing are conducted to assess their quality. This can involve dimensional measurements, surface inspection, mechanical testing, and any specific customer requirements or industry standards. -
Documentation and Traceability:
Quality assurance involves maintaining comprehensive documentation and traceability throughout the manufacturing process. This includes recording process parameters, material certifications, inspection results, and any corrective actions taken. -
Continuous Improvement:
Quality assurance is an ongoing process that emphasizes continuous improvement. This involves analysing data, identifying areas for improvement, implementing corrective actions, and leveraging feedback to enhance the overall quality of the die casting process.
By implementing robust quality assurance practices, we can ensure that aluminium die casted parts meet the required standards, performance criteria, and customer satisfaction, resulting in reliable and high-quality products.