The problem part in question was a manifold, a major component in vehicles. Gravity casting is used to make these Aluminum Manifolds. Machining and polymer infiltration processes are also used in their manufacturing.
Software simulations were also used. We ran simulations to optimise the filling of cavities through improved running system designs and predicted the occurrence of shrinkage porosity. To be more specific, porosity usually occurs on the faces or 0.5-1.0 mm deep below the faces. Good feeding, running, and gating system design reduced the common porosity issues from our manifolds.
It involves submerging a casting in a liquid, usually water, after the casting is pressurized with air. An operator examines the submerged casting and looks for any bubbles that may escape from the casting. In addition to preventing casting defects from reaching a customer, this process also prevents any casting that may contain a casting defect from reaching any assembly or production line.
The product specifications (dimensional) issue was resolved by using precise and accurate fixtures and replacing the 3-axis CNC machine with a 4-axis CNC machine. Sand core position while casting is very critical in determining the runners’ position and surface finish of the manifold.
These two factors have a strong effect on the aluminum manifolds performance and must be considered while designing the fixtures. Hence, after redesigning the fixtures and using the advanced CNC machines, product dimension issues were rectified.
Finally, leakage issues were resolved when we started using the polymer infiltration process after machining. In addition, we introduced leakage testing for each and every product before dispatching it to the customers. Thus, we applied rigorous quality checks to avoid passing faulty and defective products to the customer.
After implementing all the above-recommended solutions developed by our experts, the number of rejections and defects in manifolds has become defect-free. Our team embraced this challenge as an opportunity for improvement. We stepped in with speed, engineering creativity, and an innovative mind in this issue with the aim of producing high-quality and defect-free aluminum manifolds.
Omnidex is a World-Class Manufacturing and Engineering company that produces high quality, porosity-free casting products which are trusted by companies across different industries. Throughout the whole process, from product development to delivery, we strive to provide you with unwavering support. Providing you with unmatched diverse capabilities and experience, we help you overcome any obstacle.
Contact our Customer Service and let us know how we can help to catapult your next project to success.
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