Combining key nodes throughout the entire aluminum customization chain, this flow chart clearly illustrates the closed-loop management process from demand to delivery. Key links are labeled with responsible departments and outputs, meeting the rigorous requirements of industrial documentation.
During the Demand Matching Phase: A "site survey + 3D modeling confirmation" model is adopted, with professional software used to present product structural details and reduce communication errors.
Production Control Phase: A "double inspection system" is implemented for key processes, integrating digital twin technology to monitor production parameters and ensure process stability.
During the Finished Product Delivery Phase: A standardized packaging and traceability system is established, with each batch of products equipped with a QR code traceability label.
Client: A New Energy Vehicle Company
Requirements: Lightweight aluminum housing for power batteries, requiring a tensile strength of ≥320 MPa, a wall thickness tolerance of ≤0.05 mm, and resistance to electrolyte corrosion.
|
Customization Dimensions |
Technical Measures |
Implementation Results |
|
Material Customization |
Optimizing the 6063 Aluminum Alloy Formula by Adding 0.15% Rare Earth Elements |
Tensile Strength Reaches 335MPa |
|
Structural Optimization |
Using a one-piece molding design to reduce weld points |
12% weight reduction compared to the original design |
|
Surface treatment |
Anodizing + passivation composite process |
Electrolyte corrosion resistance up to 5000 hours |
Full-process testing
Material analysis: Direct reading spectrometer to detect alloying elements (silicon <0.05%, magnesium <0.05%) ±0.02%), grain size assessed by metallographic microscopy (±60 μm).
Performance Testing:
Mechanical Properties: Tensile Test (Yield Strength ±265 MPa, Elongation ±15%), Bend Test (Bending Radius ±6D).
Electrical Properties: Four-Terminal Conductivity (±52.5% IACS), DC Resistance (±0.0283 Ω mm²/m).
Environmental Testing: Salt Spray Test (5% NaCl Solution, No Rust for 96 Hours), Temperature Cycling (-40°C to 150°C, No Cracking for 50 Cycles).
Application Scenario: 1000kV UHV Line
Core Specifications: Conductivity ≥53% IACS, Tensile Strength ≥315MPa, Salt Spray Resistance 1000 hours.
Adopting a "37-concentrically stranded" structure, the stranding parameters were optimized through finite element simulation to reduce the skin effect of the current.
|
Indicators |
National Standard Products |
Customized Products |
Improvement |
|
Conductivity (% IACS) |
52.5 |
53.8 |
+2.5% |
|
Tensile Strength (MPa) |
≥295 |
322 |
+9.1% |
|
Salt Spray Resistance (Hours) |
≥500 |
1200 |
+140% |
Through microalloying adjustments and process optimization, we achieve customized material formulations to meet diverse performance requirements. The figure below compares the metallographic structures of typical aluminum alloys.
We have a precision mold processing center that enables integrated molding of products with complex cross-sections, extending mold life by 30% compared to industry standards.
Equipped with a full suite of testing equipment, including salt spray test chambers and electronic universal testing machines, covering over 20 core indicators, with test data uploaded to the traceability system in real time.
Establish a rapid service system featuring "24-hour demand response, 7-day solution output, and 15-day sample delivery." The following figure illustrates the response process in a timely manner.
A full lifecycle traceability file is established for each batch of products. Information such as raw material batches, process parameters, and test reports can be accessed via a QR code.
