Quality Inspection & Shipment

Die Casting Quality Inspection Standard Steps and Specifications

(Applicable to all die-cast aluminum/zinc/magnesium alloys)‌

I. Pre-Inspection Preparation‌

‌Pre-Treatment

· Deburring: Robotic automated grinding (±0.1mm precision).

· Ultrasonic cleaning: Remove residual release agents (cleanliness ≤5mg/m²).

‌Data Synchronization‌

· Load digital twin models with preset tolerance ranges (±0.05mm).

· Activate blockchain logging modules (tamper-proof records).

‌II. Core Inspection Steps‌

‌1. Dimensional Inspection‌

· ‌Automated Scanning‌:

· 3D laser scanning (10 seconds/part, compared to CAE models).

· Nanoscale probe retesting for critical holes/wall thickness (±0.02mm tolerance).

· ‌AI Judgment‌:

· Auto-classify NG/OK parts, flag deviations (red/green coding).

‌2. Material & Internal Defect Testing‌

· ‌Non-Destructive Testing‌:

· X-ray CT scanning: Detect porosity/shrinkage (5μm resolution).

· Spectrometer: Verify alloy composition (Al/Mg/Zn content ±0.3%).

· ‌Destructive Sampling‌ (1 per 500 parts):

· Metallographic analysis (grain size ≥Grade 7 required).

‌3. Surface Quality Inspection‌

· ‌AI Vision System‌:

· Hyperspectral imaging for cracks/scratches (detects 0.01mm² defects).

· Laser roughness scanning (Ra≤1.6μm, Sa≤2.0μm).

· ‌Adhesion Test‌ (for coated parts):

· Cross-cut test (ISO 2409:2025, Grade 0 compliance).

‌4. Functional Validation‌

· ‌Simulated Load Testing‌:

· Apply 120% working load via hydraulic press (30s hold, deformation ≤0.1%).

· Fatigue testing (100k cycles) with IoT crack-monitoring sensors.

‌III. Post-Inspection Handling‌

‌Data Archiving‌

· Sync results to MES system (auto-generate SPC control charts)

· Blockchain certification (timestamp, equipment ID, operator e-signature).

‌Part Grading‌

· OK parts: VCI anti-rust packaging + QR traceability labels.

· NG parts: AI-sorted by defect type, routed to remelt/rework.

‌IV. Compliance Requirements‌

Mandatory Tests‌ (violations trigger EU 2025/EMD penalties):

· 100% inspection: X-ray internal defects, AI surface scanning.

· Per-batch tests: Spectrometer analysis, blockchain data upload.

Tolerance Limits‌:

· Dimensional deviation >±0.1mm: Immediate scrapping (no rework allowed).

· Porosity rate >0.3%: Full batch remelting.

‌V. Legacy vs. 2025 Smart Inspection Comparison‌

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Note: Daily calibration required for inspection equipment using NIST 2025 standard gauge blocks.