Customer Requirement Analysis
The customer requested a custom concave aluminum block with no internal defects, requiring ultrasonic testing for flaw detection. We carefully understood the customer’s application and technical requirements, formulated a production plan that met their needs, and selected high-performance 2024 aluminum alloy as the raw material.
Selection of Raw Materials
2024 aluminum alloy is known for its high strength, good fatigue performance, and excellent crack resistance, making it a commonly used material in the aerospace industry. We rigorously selected 2024 aluminum billets that were free of impurities and had consistent quality to ensure the chemical composition and mechanical properties met the required standards.
Forging Process Control
To ensure the mechanical properties and internal quality of the concave aluminum block, we adopted precision forging processes, strictly controlling the following key steps:
Heating: The aluminum billet is heated to the optimal forging temperature range to avoid overheating or underheating, ensuring uniformity in the internal grain structure.
Forging: The concave aluminum block is forged step by step using high-precision molds. Multiple heat treatments and annealing processes are performed to ensure the stability of the material structure and the dimensional accuracy of the component.
Cooling: After forging, a controlled cooling process is applied to relieve internal residual stresses and enhance the material’s overall performance.
Nondestructive Testing
After forging, the concave aluminum block underwent ultrasonic testing to ensure there were no internal cracks, air pockets, or other defects. Once the test was passed, the product quality was validated and met the customer’s requirements.
2024 aluminum alloy has very high yield strength and tensile strength, making it suitable for structural components subjected to heavy loads.
Good Fatigue Resistance: Ideal for components that require repetitive loading.
Machinability: It has good machinability and formability, making it easy to process and shape.
Corrosion Resistance: While its corrosion resistance is moderate, it can be significantly enhanced through surface treatments.
Typical Applications:
Aerospace Industry: Used for manufacturing structural components such as wings and fuselage frames.
Transportation: Applied in automotive parts like wheels and chassis.
Industrial Machinery: Used for high-strength, precision molds and equipment components.
Through the strict production and testing processes described above, we successfully completed the custom concave aluminum block. The product quality met the customer’s expectations and demonstrated the outstanding performance of 2024 aluminum alloy.