How to Make Compressor Housing by Aluminum Casting Process In China
Product Description
The compressor housing, a critical component in turbochargers, plays a vital role in ensuring efficient air compression and boosting engine performance. Manufacturing these housings requires precision, durability, and optimal design to meet exacting industry standards. Among the various manufacturing methods available, the aluminum casting process stands out as a reliable and cost-effective solution. In this blog, we will explore how compressor housings are made using the aluminum casting process and highlight the quality control advantages and expertise of Dongrun Casting Industry Co., Ltd in this domain.
The Aluminum Casting Process for Compressor Housing
Aluminum casting is a manufacturing process where molten aluminum is poured into a mold to create complex, lightweight, and durable components. For compressor housings, this process is particularly advantageous due to aluminum's excellent strength-to-weight ratio, corrosion resistance, and thermal conductivity. Below is an overview of the key steps involved in producing compressor housings via the aluminum casting process:
1. Design and Mold Creation
The process begins with designing the compressor housing using advanced CAD (Computer-Aided Design) software. The design must account for functionality, structural integrity, and manufacturability. Once finalized, a mold is created based on the design. The mold can be made from sand, metal, or other materials depending on the casting method (e.g., sand casting or permanent mold casting).
2. Melting and Pouring
High-quality aluminum alloys are melted in a furnace at controlled temperatures to achieve the desired molten state. The molten aluminum is then carefully poured into the prepared mold. At this stage, precision is crucial to ensure uniform filling and prevent defects such as air entrapment or incomplete casting.
3. Solidification and Cooling
Once poured, the molten aluminum begins to solidify within the mold. The cooling process must be carefully monitored to ensure even solidification and prevent internal stresses or cracks.
4. Demolding
After the aluminum has fully solidified, the mold is removed to reveal the raw compressor housing. Depending on the type of mold used (e.g., sand molds), this step may involve breaking or disassembling the mold.
5. Finishing and Machining
The raw casting undergoes post-processing steps such as trimming excess material, deburring, and surface finishing. Precision machining is then performed to achieve tight tolerances and ensure that the compressor housing meets exact specifications.
Quality Control: Dongrun Casting Industry Co., Ltd's Expertise
Producing high-quality compressor housings requires stringent quality control measures at every stage of the aluminum casting process. Dongrun Casting Industry Co., Ltd has established itself as an industry leader by leveraging its extensive experience and robust quality control systems. Here are some of the key advantages that set Dongrun apart:
1. Advanced Casting Techniques
Dongrun employs cutting-edge casting technologies such as sand casting, permanent mold casting, and gravity die casting to meet diverse customer requirements. Each method is tailored to ensure optimal results for specific applications.
2. Material Selection Expertise
The choice of aluminum alloy is critical for achieving desired properties such as strength, corrosion resistance, and thermal conductivity. Dongrun's team of metallurgical experts ensures that only high-grade alloys are used for compressor housings.
3. Precision Machining Capabilities
Dongrun's state-of-the-art CNC machining centers enable precise finishing of compressor housings. This ensures that each component meets tight dimensional tolerances and fits seamlessly into turbocharger systems.
4. Stringent Inspection Protocols
Quality control at Dongrun begins with raw material inspection and continues through every stage of production. Non-destructive testing (NDT), such as X-ray inspection and ultrasonic testing, is used to detect internal defects in castings. Dimensional inspections are performed using advanced measurement tools to verify compliance with design specifications.
5. Experienced Workforce
Dongrun boasts a highly skilled workforce with years of experience in aluminum casting and machining. Their expertise ensures consistent quality and efficient production processes.
6. Commitment to Sustainability
As environmental concerns grow, Dongrun is committed to sustainable manufacturing practices. The company employs energy-efficient melting furnaces, recycles scrap materials, and adheres to strict environmental regulations.
Why Choose Aluminum Casting for Compressor Housings?
Aluminum casting offers several advantages that make it an ideal choice for manufacturing compressor housings:
- Lightweight Design: Aluminum’s low density reduces overall weight without compromising strength, making it ideal for automotive applications.
- Complex Geometry:The casting process allows for the creation of intricate shapes and designs that would be difficult or expensive to achieve through other methods.
- Cost-Effectiveness:Compared to machining from solid blocks or forging, aluminum casting is more economical for producing complex components in large quantities.
- Thermal Efficiency:Aluminum’s excellent thermal conductivity helps dissipate heat efficiently, which is crucial for turbocharger performance.
- Corrosion Resistance:Aluminum’s natural oxide layer protects it from corrosion, ensuring long service life even in harsh environments.
The aluminum casting process is a proven method for manufacturing high-performance compressor housings that meet the demands of modern turbocharger systems. With its advanced capabilities, stringent quality control measures, and extensive experience, Dongrun Casting Industry Co., Ltd has established itself as a trusted partner for producing top-quality aluminum cast components.
Whether you’re looking for custom-designed compressor housings or need a reliable supplier for large-scale production, Dongrun’s expertise ensures that your requirements are met with precision and efficiency. By choosing Dongrun, you gain access to a team committed to delivering excellence at every stage of the manufacturing process.
For more information about Dongrun Casting Industry Co., Ltd’s services or to discuss your project requirements, feel free to contact their team today!
Factory Cabability
| Material | 1. Sand casting&Gravity casting&Low pressure die casting: |
| Service | Sand casting, Gravity casting, high pressure die casting,low pressure die casting and CNC Machining casting. |
Equipment of Casting | 1. High pressure die casting machining:125T/180T/250T/280T/500T/800T/1250T 2. Gravity casting machine: 7 production lines 3. Low pressure die casting machining: 1 production line 4. Sand casting machine: 6 production lines 5. Degassing equipment and opportunities to refine the material 6. Machining: 9 Sets CNC Machines; 5 sets Milling machines; 3 setsTurning machines; 20 sets drill and tap machines |
| Testing Facility | Spectrometer, Tensile test device, Hardness test device, CMM, X-Ray, Leaking test device |
Precision Machining | CNC turning, Milling, Drilling, Grinding, Cutting, Reaming and Threading |
| Finished | Polishing, Sand blasting, Heat treatment, Painting, Powder coating, Anodizing, Electroplating, Chrome plating, Mirror polishing. |
| Products | All kinds of Cast aluminum productions: Including Vehicle industry,Medical device industry, Marine industry, Lighting industry,Oil&Gas Transporttation industry, Electric Utility & Communication Industries, Architectural industry and Furniture industry so on |
Production Images
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Company Equipment
From Casting to Machining, One-stop Solutions for your designs
Packing & Shipping
Casting parts are very heavy, package must be strong. Our package material is wooden crate which is Fumigation free.
And we can pack productions as customers' requirements
Why Choose Us
❖ More than 25 years in castings and machining process; so we have much experience for your projects.
❖ Passed ISO9001 : 2015 & TS16949 : 2009
❖ Have four casting types in our factory; you can find the four process in one factory, save cost for your company
❖ From Casting to Finished surface, Owned casting, polishing and plating workshops, one-stop, We can offer Good quality and strict delivery time.
❖ With samples and order: We can offer dimension report, Chemical composition and Mechanical properties
❖ Control material with spectral and thermal analysis equipment (density and processing)
❖ Spectral analysis of raw material and liquid melt, batch before casting.
❖ Transportation Advantage:
A) Near Sea Port and Air Port-Ningbo Sea Port and Yiwu Airport or Hangzhou Airport;
B ) From Shanghai to our factory by Fast train directly, takes two and half hours; From Hangzhou to our factory, only takes one hour
FAQ
Q1. Are you trading company or manufacturer
We are factory, We are only doing cast aluminum and machining more than 20years, we have much experience in this industry. If you find some "factory" can do kinds of material castings(steel, iron,stainless,cooper.......), we are sure they are trading company. If you have other material castings to do, we can introduce for you free. It is our pleasure that we can help you.
Q2. How to get quotation from your factory?
We need a 3D CAD solid model to prepare a First Quote interactive quote. All of the Firstcut processes are dependent on good 3D CAD solid models. Two-dimensional (2D) drawings are not adequate for quoting or making parts.
We can accept native SolidWorks (.sldprt) or ProE (.prt) files as well as solid 3D CAD models from other CAD systems output in IGES (.igs), STEP (.stp), ACIS (.sat) or Parasolid (.x_t or .x_b) format.
Q3. When can I get the price?
We usually quote within 48 hours after we get your inquiry. If you are very urgent, please call us or tell us in your email so that we will regard your inquiry priority.
Q4. How about your lead time?
1): Toolings &Samples
Sand Casting will take 15 to 30 days after receiving your advance payment.
Gravity casting, low pressure die casting, high pressure die casting will take 30 to 60days after receiving your advance payment.
2) Mass production
The specific delivery time depends on the items and the quantity of your order.
Q5. Can you produce according to the samples?
Yes, we can produce by your samples or technical drawings. We can build drawings for you after we get your samples too.
Q6. What is your sample policy?
We can supply 1pcs sample free (value under USD15/PCS) after we finish as your drawings, but the customers have to pay the freight cost. If you need more samples, you have to pay the samples cost.
Q7. Can we use your current tooling? Or can we get samples which are shown on your website?
No, we can't do it.
We only accept OEM orders and do casting parts as your drawings or samples. We can't sell any production or design to any third body. We can't show any photos on website without our clients' allowance. We signed NDA with all clients, all tooling and drawings belong our clients. We only use the tooling to make productions for one client. The client can take way the tooling any time after tooling cost.
Q8. Do you test all your goods before delivery?
Yes, we have 100% test before delivery
Q9: How do you make our business long-term and good relationship?
We keep good quality and competitive price to ensure our customers benefit ;
We respect every customer as our friend and we sincerely do business and make friends with them, no matter where they come from.
