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Finishing
 Introduction to Die Casting Material Processing Protocols |  |
| Zinc alloy die casting procedures |  | Original zinc alloy
domestic -"K2" made by K.T.L. Metal Industrial Corp.;imported - "Map" made by an Australian company | | Major compositions
aluminum, less than 3.9%~4.3%; copper, less than 0.03%; magnesium, 0.03%~0.06%;lead, less than 0.003%; iron, less than 0.075%; cadmium, less than 0.002%; tin, lessthan 0.001%; residual zinc, about 95%. | | Furnace
mostly heat on kerosene furnace, melting point is between 430 -450. | | Molding
based on each mold's characteristics to adjust filling parameters such as pressure and mold releasing time. | | Die casting filling
based on each mold's characteristics and size to adjust filling times. | | Trimming
after filling the die casting, let the object cool down; after cooling down, trim the object either manually or via molding machine; to distinguish and separate the fillings (fillings are recyclable with recovery rate approximately 80%). | | Vibratory grinding
according to our client's request and order, sort out and categorize the filled objects of die casting; clean and clear the edges by vibration. Based on the size and material of the objects, vibration can be further divided into vibration painting - for electro-coating; and light vibration - for burnish and electroplating. | | | TOP |
| Introduction to Die Casting Painting Processing Protocol |  |
| Procedures for painting on zinc alloy | | Water bath and cleansing
after vibration, zinc alloy must first be immersed in the degreasing agent to cleanse off the grease and any impurities left on its surface. | | Ultrasonic cleansing
further to cleanse off the impurities left on the surface of the zinc alloy by placing the alloy in an ultrasonic cleaner filled with degreasing agent. | | Water bath
let the zinc alloy sit in a water bath; this will wash off the degreasing agent left on the surface of the alloy. | | Acid pickling
let the zinc alloy immerse in a sulfuric acid solution; this will neutralize the layer of the fresh paint painted on the alloy; therefore, this will increase adhesiveness of the fresh paint to the alloy. | | Water bath
let the zinc alloy sit in a water bath; this will wash off the sulfuric acid left on the surface of the alloy. | | Coating
let the baked paint on the finished product oxidize by immersing it in chromium solution. | | Water bath
let the zinc alloy sit in a water bath; this will wash off the chromium solution left on the surface of the alloy. | | Drying
dry the wet zinc alloy in an oven (at around 120) . | | Mixing
mix and dilute the paints in order to get the desired color based on the order. | | Hanging
select an appropriate hanging rack depending on object's shape and size. | | Spraying
Use electrostatic spraying gun or air-pressure spraying gun to spray the paint on the object. | | Baking
it takes approximately 30 minutes at 120. | | Off the rack
After cooling off, remove the baked finished product off the rack. | | Packaging
Select appropriate packaging for the object based on its shape and size . | | | TOP |
| Introduction to Die Casting and Black Electro-coating Processing Protocols |  |
| Hanging
select an appropriate hanging rack depending on object's shape and size. | | Water bath and cleansing
after vibration, zinc alloy must first be immersed in the degreasing agent to cleanse off the grease and any impurities left on its surface. | | Ultrasonic cleansing
further to cleanse off the impurities left on the surface of the zinc alloy by placing the alloy in an ultrasonic cleaner filled with degreasing agent (twice). | | Water bath
immerse the zinc alloy in a hanging rack in a water bath; this will wash off the degreasing agent left on the surface of the alloy (threefold). | | Surface activation
immerse the hanging rack in Titanium (Ti) compound solution; this will increase the positive charge of the object on the electro-deposit coating surface, enhance the activity for better activation. | | Chemical processing
immerse the hanging rack in zinc phosphate coating solution for chemical processing; this may increase the density and tolerance to erosion. | | Wash off with water
immerse the zinc alloy in a hanging rack in a water bath; this will wash off the zinc phosphate coating residue left on the surface of the alloy (twice). | | Electro-deposit coating
coating with black anion electro-coating which provide better tolerance for erosion and better sealing. | | Wash off with water
Immersion of the zinc alloy in a hanging rack in a water bath; this will wash off the zinc phosphate coating residue left on the surface of the alloy (twice) | | Baking
approximately 30 minutes at 170. | | Off the rack
after cooling off, remove the baked finished product off the rack. | | Packaging
select appropriate packaging for the object based on its shape and size. | | | TOP |
| Procedure of anodizing mist nickel, nickel, and nickel processing on zinc alloy |  |
| Burnish
after light vibration, zinc alloy will go through burnish process based on the request to smooth and polish the surface via lapping wax on lapping machine. | | Hanging
select an appropriate hanging rack depending on object's shape and size. | | Ultrasonic cleansing
further to cleanse off the lapping wax, grease, and impurities left on the surface of the zinc alloy by placing the alloy in an ultrasonic cleaner filled with degreasing agent (twice) | | Water bath
wash off the degreasing agent on the surface of the zinc alloy with water in the rack. | | Electrolysis
use EDTA as the last chemical cleansing agent to electrolyze pre-anodized object. | | Copper-plating
anodizing copper to enhance the density and sealing. | | Phosphoric acid immersion
wash off cyanide with phosphoric reacting agent. | | Copper pyrophosphate treatment
anodizing copper pyrophosphate to smooth out the unevenness of the surface. | | Sulfuric acid immersion
wash off copper pyrophosphate with sulfuric acid; this strengthens the adhesion. | | Nickel-plating
lusty nickel | | Nickel-plating
misty nickel. | | Sodium carbonate immersion
immerse in sodium carbonate solution to neutralize the solution and prevent acid feedback. | | Wash off with water
wash off the chemical residue left on the surface of the alloy with water (more than twice). | | Drying
drying at around 120 for 30 minutes . | | Off the rack
After cooling off, remove the baked finished product off the rack. | | Nickle lining
Use lapping machine with 3M's 150# nylon burnishing wheel 150# to burnish desired track. | | Packaging
Select appropriate packaging for the object based on its shape and size. | | | TOP |
| Zinc alloy anodizing with mist nickel , mist black nickel processing |  |
| Sand blasting
sandblast the vibrated zinc alloy according to the request on the order (sand blaster, glass sand) | | Hanging
select an appropriate hanging rack depending on object's shape and size. | | Ultrasonic cleansing
further to cleanse off the lapping wax, grease, and impurities left on the surface of the zinc alloy by placing the alloy in an ultrasonic cleaner filled with degreasing agent (twice) | | Water wash
wash off the chemical agent left on the surface of the alloy with water in the rack (threefold). | | Electrolysis
use EDTA as the last chemical cleansing agent to electrolyze pre-anodized object. | | Copper-plating
anodizing copper to enhance the density and adhesion capacity. | | Phosphoric acid immersion
wash off cyanide with phosphoric reacting agent. | | Copper pyrophosphate treatment
anodizing copper pyrophosphate to smooth out the unevenness of the surface. | | Sulfuric acid immersion
wash off copper pyrophosphate with sulfuric acid; this strengthens the adhesion. | | Nickle-plating
misty nickel, the same process goes to black mist nickel. | | Nickel-plating
black misty nickel, the process does not apply on mist nickel. | | Immersion in potassium chromium solution
immersing in potassium chromium solution to create a coating to prevent discolorations. | | Wash off with water
wash off the chemical residue left on the surface of the alloy with water (more than twice). | | Drying
at 110 for approximately 30 minutes | | Spraying
Spraying transparent paint to maintain original color; this prevents discoloration due to oxidation. | | Drying
at 120 for approximately 30 minutes | | Off the rack
After cooling off, remove the baked finished product off the rack. | | Packaging
Select appropriate packaging for the object based on its shape and size. | | | TOP |
| Zinc alloy anodizing gold and chromium processing protocol |  |
| Burnish
After light vibration, zinc alloy will go through burnish to smooth and polish surface via lapping wax on lapping machine. | | Hanging
select an appropriate hanging rack depending on object's shape and size. | | Ultrasonic cleansing
further to cleanse off the lapping wax, grease, and impurities left on the surface of the zinc alloy by placing the alloy in an ultrasonic cleaner filled with degreasing agent (twice). | | Water bath
wash off the degreasing agent on the surface of the zinc alloy with water in the rack (threefold). | | Electrolysis
use EDTA as the last chemical cleansing agent to electrolyze pre-anodized object. | | Copper-plating
anodizing copper to enhance density and adherent capacity. | | Phosphoric acid immersion
wash off cyanide with phosphoric reacting agent. | | Copper Pyrophosphate Treatment
anodizing copper pyrophosphate to smooth out the unevenness of the surface. | | Sulfuric acid immersion
wash off copper pyrophosphate with sulfuric acid; this strengthens the bonding. | | Nickel-plating
lusty nickel, same practice with anodizing chromium. | | Chromate treatment
lusty chromium, this process does not apply on anodizing gold. | | Pre-anodizing gold
this may strengthen the bonding, this process does not apply on anodizing chromium. | | Gold-plating
add copper to pure gold to become 16K gold, the process does not apply on anodizing chromium. | | Immersing in potassium chromium solution
immersing in potassium chromium solution to create a coating to prevent discolorations, this process does not apply on anodizing chromium. | | Wash off with water
wash off the chemical residue left on the surface of the alloy with water (more than twice). | | Drying
at 110 for approximately 30 minutes | | Off the rack
After cooling off, remove the baked finished product off the rack. | | Packaging
Select appropriate packaging for the object based on its shape and size. | | | TOP |
| Zinc alloy anodizing with copper, black nickel processing |  |
| Burnish
after light vibration, zinc alloy will go through burnish to smooth the surface based on customer request via lapping wax on lapping machine. | | Hanging
select an appropriate hanging rack depending on object's shape and size. | | Ultrasonic cleansing
further to cleanse off the lapping wax, grease, and impurities left on the surface of the zinc alloy by placing the alloy in an ultrasonic cleaner filled with degreasing agent (twice). | | Water bath
wash off the degreasing agent on the surface of the zinc alloy with water in the rack (threefold). | | Electrolysis
use EDTA as the last chemical cleansing agent to electrolyze pre-anodized object. | | Copper-plating
anodizing copper to enhance density and adhesion capacity. | | Phosphoric acid immersion
wash off cyanide with phosphoric reacting agent. | | Copper Pyrophosphate Treatment
anodizing copper pyrophosphate to smooth out the unevenness of the surface. | | Sulfuric acid immersion
wash off copper pyrophosphate with sulfuric acid; this strengthens the bonding. | | Nickel-plating
lusty nickel, same process goes to copper and black nickel. | | Copper-plating
lusty copper. | | Anodizing black nickel
lusty black nickel, the protocol does not apply on copper. | | Immersing in potassium chromium solution
immersing in potassium chromium solution to create a coating on the alloy to prevent discolorations. | | Wash off with water
wash off the chemical residue left on the surface of the alloy with water (more than twice). | | Drying
at 110 for approximately 30 minutes | | Spraying
spraying transparent paint to maintain original color; this prevents discoloration due to oxidation. | | Drying
at 120 for approximately 30 minutes | | Off the rack
after cooling off, remove the baked finished product off the rack. | | Packaging
select appropriate packaging for the object based on its shape and size. | | | TOP |
| Zinc alloy anodizing with tin alloy protocol |  |
| Burnish
after light vibration zinc alloy will go through burnish to smooth the surface based on customer request via lapping wax on lapping machine. | | Hanging
select an appropriate hanging rack depending on object's shape and size. | | Ultrasonic cleansing
further to cleanse off the lapping wax, grease, and impurities left on the surface of the zinc alloy by placing the alloy in an ultrasonic cleaner filled with degreasing agent (twice). | | Water bath
wash off the degreasing agent on the surface of the zinc alloy with water in the rack (threefold). | | Electrolysis
use EDTA as the last chemical cleansing agent to electrolyze pre-anodized object. | | Copper-plating
anodizing copper to enhance density and adhesion capacity. | | Phosphoric acid immersion
wash off cyanide with phosphoric reacting agent. | | Copper Pyrophosphate Treatment
anodizing copper pyrophosphate to smooth out the unevenness of the surface. | | Sulfuric acid immersion
wash off copper pyrophosphate with sulfuric acid; this strengthens the bonding. | | Nickel-plating
lusty nickel. | | Copper-plating
lusty tin copper | | Anodizing black nickel
lusty black nickel. | | Anodizing black nickel
lusty black nickel, this protocol does not apply on copper. | | Wash off with water
wash off the chemical residue left on the surface of the alloy with water (more than twice). | | Drying
at 110 for approximately 30 minutes | | Off the rack
after cooling off, remove the baked finished product off the rack. | | Burning tin alloy
use lapping machine with melon wheel to partially remove the upper black nickel. | | Wash off
same cleansing procedure as pre-baking | | Spraying
spraying transparent paint to maintain original color; this prevents discoloration due to oxidation. | | Drying
at 120 for approximately 30 minutes | | Off the rack
after cooling off, remove the baked finished product off the rack. | | Packaging
Select appropriate packaging for the object based on its shape and size | | | TOP |
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Dial
Finishing
