Components, once manufactured, are passed through different surface finishing processes, for which chrome plating is also opted.

These surface finishing processes always enhance the durability and look of the component. If you want to learn about chrome plating, you can go through this guide below.

What is Chrome Plating?

Chrome plating is a method in which a layer of chromium is applied to a metal through electroplating. This process improves the durability and toughness of the component and also makes it corrosion-resistant.

The Chrome Plating Process

Chrome plating is a step-by-step process, and the section below details it.

• The first stage involves cleaning the component by degreasing it using an abrasive cleaner. It helps eliminate dirt, grease, or any other impurity on the surface.
• The component to be chrome plated is mounted on a fixture that can conduct electricity, and it is connected to the circuit for the process.
• An electro-cleaning solution is added, and the component is submerged in it. The component is then connected to the power supply. When the current passes, the residual impurities are removed.
• The component is then introduced to a chromic acid bath in the presence of electricity, and chromium ions deposit on the surface, creating a chrome layer.
• The component is then rinsed so that any residue of the chemicals is removed.
• The chrome-plated component is then polished and buffed to achieve the desired finish and is inspected thoroughly.

Benefits of Chrome Plating

Chrome plating offers versatile benefits, and some of these benefits are as follows:

• Hard chrome plating offers hardness, which is more than metallic coatings, and can withstand high stress.
• The addition of a thick layer of chromium plating protects the components from wear and tear when they are exposed to chemicals.
• Hard chrome plating, when it comes in contact with graphites, metals, and polymers, tends to have less friction and hence is suitable for moving parts.
• When the chrome plating gets damaged, it can be replaced easily and the lifespan of the parts can be enhanced.

Key Types of Chrome Plating

There are different types of chrome plating, and some of these are as follows:

Cromatura dura

Hard chrome plating is the application of a thick chromium layer to the steel component. This electroplating process involves submerging the component in chromic acid and depositing a layer of chrome.

Hard chrome plating enhances the life of the components and enhances their resistance against corrosion. It even helps with oxidation resistance and chemical inertness.

Decorative Chrome Plating

Decorative chrome plating, as the name suggests, enhances the aesthetic beauty of the components. It is a thin layer and, hence, less durable.

The process of decorative chrome plating starts with nickel electroplating and sometimes even copper plating. It adds smoothness and reflectiveness before the chrome plating.

Thin Dense Chrome Plating

Thin dense chrome plating is a coating that is used in manufacturing applications.

The chromium material is electroplated on the components and has a surface texture that is microcracked and micronodular. This coating enhances the life and operational efficiency of the components.

Suitable Materials for Chrome Plating

Chrome plating can be carried out on various materials, but the main materials usually opted for chrome plating are as follows:

Acciaio

Acciaio is a very common material which is used in different industries. After adding a layer of chrome plating, the steel components became durable, and resistant to wear and corrosion.

Alluminio

Aluminum is mostly chosen because it is strong and lightweight. Therefore, in heavy-duty applications, aluminum proves to be a suitable choice.

When aluminum components are chrome-plated, they become resistant to corrosion and durable. Automobile parts like wheels and trims, and even aerospace components made using aluminum, are chrome-plated.

Plastica

All types of plastics are not good conductors of electricity, but some of them, like ABS, can be chrome plated. It is used in the electronics and automobile industry and can offer a metallic look, being lightweight due to chrome plating.

The interior and exterior of cars and various household items manufactured using ABS are chrome plated.

Applications of Chrome Plating

Chrome plating is observed in different industries, and some of these are as follows:

Industria automobilistica

Chrome plating is used in the automotive sector for functional and decorative purposes.

The components of vehicles, like trims, grilles, bumpers, and exhaust, are all chrome-plated. The reason behind their chrome plating is to enhance the resistance against wear and tear and give them a shiny look.

Industria aerospaziale

The aerospace industry needs strength-oriented components that are heat-resistant and lightweight. Hence, aluminum and steel, which can be chrome-plated, are commonly used in this industry.

The chrome-plated aerospace components can resist friction and corrosion and even withstand stress. Components like engine parts, landing gear, and hydraulic systems are chrome-plated.

Industria medica

Chrome plating is also used to add a protective layer to medical components and surgical tools. It helps to enhance the durability and sterilization of these components.

The chrome-plated tools are highly corrosion-resistant and can withstand chemical use and sterilization.

Conclusione

The finishing process of chrome plating gives the components new life and protects them with a protective layer. These components have a durable life span and can be used for different applications.

Start Your Chrome Plating Project with DEK

Are you starting a new project requiring chrome plating on the components? DEK can be your go-to choice as we offer high-quality secondary finishing processes, and chrome plating is also one of them.

So, give us a chance to enhance the properties of your components by adding a chrome layer to them.

Domande frequenti

Is chrome plating expensive?

Compared to other electroplating processes, chrome plating is a little expensive as it is a complex process.

How to remove chrome plating?

Chrome-plated components can be submerged in hydrochloric acid to remove the plating.

How is chrome plating done on aluminum?

Aluminum components are first copper-plated and then subjected to the chromium-plating process.

What’s the difference between hard chrome and decorative chrome plating?

Hard chrome plating is thick and focused on the performance and function of the component. Decorative chrome plating is thinner and less durable. It enhances the look and aesthetics of the parts.

What types of chrome plating should you choose?

Every type of chrome plating has a different purpose. The decorative chrome plating is used for coating the decorative components whereas the hard chrome plating is used for a durable life.

Based on your application requirements, you can choose the type of chrome plating.

Are you planning to start a new project with glass-filled nylon and want to learn about it? You are at the right place then.

Glass-filled nylon is a material used in different applications for its versatile characteristics. This guide below has the answers to all your questions about glass-filled nylon, so let's read.

What is Glass Filled Nylon?

Glass filled nylon is a combination of nylon and glass. It is nylon with glass reinforced on it. It is known for various properties found in glass and nylon. It exhibits mechanical damping followed by excellent creep resistance.

It is also opted for the improved heat distortion temperature it offers. When glass fibers are mixed with nylon resins, a composite material is formed.

It is used for components that are high-performing. The glass fibers used in the material range between 10 to 40% of the total weight.

Properties of Glass Filled Nylon

Glass-filled nylon has been chosen for different projects due to its excellent properties. Some of its properties are as follows:

• Glass-filled nylon offers excellent strength and fatigue resistance.
• It does not deform easily and is also warp-resistant due to its low thermal expansion.
• Glass-filled nylon can work under a wide temperature range and maintains its dimensional stability as well.
• It offers seamless creep resistance, and even when subjected to mechanical pressure, it prevents deformation.
• It is highly shock absorbing and can even resist vibration, so it is suitable for applications that are vibration-sensitive.

Advantages of Glass Filled Nylon

Glass-filled nylon offers multiple benefits, which is why it is used in many applications, and some of these are as follows:

High Moldability

Glass-filled nylon can be molded in versatile shapes and designs, regardless of its complexity. It can be used for injection molding, and the required product is achieved.

High Electrical Insulation

Glass-filled nylon has seamless electrical insulation. It is, therefore, used for electronic component manufacturing.

Enhanced Strength

It has high tensile strength and an enhanced modulus of elasticity, which makes it suitable for applications that require load-bearing capacity and structural integrity.

Excellent Impact Resistance

The glass and nylon combination improves cracking resistance and allows it to handle more pressure. Hence, applications that involve dynamic loading find it suitable.

Stabilità dimensionale elevata

The addition of glass fibers in the nylon lowers the coefficient of thermal expansion. It also makes the material dimensionally stable.

Hence, there is a reduced chance of warping, expansion, or shrinking due to the changes in temperature.

Disadvantages of Glass Filled Nylon

Glass-filled nylon has ample benefits, but there are some downsides of it, too, which are as follows:

• Glass-filled nylon has a higher weight, which is about 15% more than nylon, which makes it unstable for low-weight applications.
• It has anisotropic properties, which cause misalignment of glass fiber in the machining process, leading to varied stiffness through different axes of the component.
• The impact of glass fiber on the mating surface may be abrasive, and hence, it is not suitable for sliding applications.
• It absorbs moisture, which is why structural weakness is observed in it when subjected to wet environments.
• It's expensive compared to the unfilled nylon in most cases.
• It is highly brittle, and under a high-stress environment, it may fracture or crack.

How is Glass-Filled Nylon Used in Parts Production?

The process of manufacturing glass-filled nylon is discussed below.

Lavorazione CNC

Lavorazione CNC is a very ideal process when it comes to manufacturing components using glass-filled nylon.

It is, however, suggested that carbide-based cutting tools be used when machining glass-filled nylon due to its abrasive properties. Moreover, during machining, it is suggested to even work on low cutting speed, which also offers optimal cuts with low tool wear.

Stampa 3D

3D printing is an additive manufacturing process that utilizes glass-filled nylon and manufactures 3D components. The process works by adding layer after layer using different 3D printing methods.

The nozzles for 3D printing that work with glass-filled nylon should be made of hardened steel to deal with the abrasive nature of the material.

Stampaggio a iniezione

The injection molding process uses different types of glass-filled nylon. The material offers high abrasion. Hence, the materials used for injection molding tools must be able to deal with this abrasion and are preferred to be made using hard steel.

Common Types of Glass-Filled Nylon

There are different grades of glass-filled nylon, and each type has its own properties and uses. Some of these common grades of glass-filled nylon are as follows:

PA 6/6 GF

PA 6/6 GF has about 15 to 50% glass material, and it has excellent impact resistance, rigidity, and thermal properties. It also has good thermal stability and moisture resistance.

Hence, it is widely used in precision-oriented applications and load-bearing parts like machine components and pulleys.

PA 6 GF

PA 6 GF has a ratio of glass of about 15 to 45% combined with nylon 6. The addition of glass fiber improves the impact resistance, moisture absorption, and mechanical performance of the material. It is then used in engine guards and plastic enclosures.

PA 12 GF

PA 12 GF has PA 12 as a base material, and its glass is enforced in a ratio of up to 30%. It offers high chemical resistance and also has a low melting point with limited strength.

However, it is suitable for such applications which require stable chemical properties rather than mechanical ones.

PA 46 GF

PA 46 GF is high-performing glass-filled nylon. It has high wear resistance and excellent thermal stability. It is suitable for most applications, like making circuit breaker components for electric motors and sensors.

PA 6/6 GF FR

PA 6/6 GF FR has flame-retardant properties. Hence, it is suitable for applications in which safety from fire hazards is needed. It is mostly used in appliances and electrical circuits.

Applications of Glass Reinforced Nylon

There are many applications of glass-filled nylon, and some of these are as follows:

Applicazioni industriali: It is used in industries for manufacturing different parts like pipes, valves, bushings, conveyor belts and other components for machinery.

Automobile: The glass filled nylon is used in the automobile industry to make car components like gears, fan blades, fuel tank caps, and latches.

Elettronica: Glass-filled nylon is used for earphones, printers, cameras, printer cartridges, and other electronic components.

Household: It is suitable for households manufacturing consumer products like vacuum cleaners, water purifiers, combs, and other appliances.

What’s the Difference Between Nylon 12 and Glass-Filled Nylon?

Glass-filled nylon is a nylon material that consists of glass fibers, making it stronger than nylon. It has high rigidity and is hence suitable for components that need excellent mechanical performance.

Nylon 12, on the other hand, offers impact resistance, mechanical strength, and resistance against chemicals. However, it has low friction and moisture absorption, which makes it work well in humid environments.

Get Machined Glass-Filled Nylon Parts at DEK

Glass filled nylon has versatile uses in different industries, and if you are looking for machine components made of glass filled nylon, you can contact DEK.

We design and manufacture custom glass filled nylon components for your projects as specified by you. We have advanced manufacturing processes, high-quality materials, and expert engineers.

Conclusione

As you have read the guide above, it would have been sufficient to help you with your new project related to glass filled nylon.

It is very crucial to understand the properties, manufacturing processes, and applications of this material before you choose it for your projects.

Domande frequenti

How does glass-filled nylon compare to unfilled nylon?

Glass-filled nylon offers better strength, creep resistance, and dampening properties compared to unfilled nylon.

Is glass-filled nylon stronger than polymer?

Yes, glass-filled nylon offers superior strength compared to polymer.

How do you choose glass-filled nylon grade for machining applications?

Glass filled nylon is hard and strong with a high glass-fiber ratio, but the harder it is, the more difficult it is to machine.

What safety precautions are important when machining glass-filled nylon?

Glass-filled nylon, when machined, produces a lot of dust which can contaminate the environment of the workshop. It requires proper filtration and ventilation when machining it.

L'alluminio ha particolari proprietà fisiche e chimiche, non solo leggerezza, forte consistenza, resistenza alla corrosione, buona duttilità, conducibilità elettrica, conducibilità termica, resistenza al calore e resistenza alle radiazioni nucleari, è lo sviluppo dell'economia nazionale di importanti materie prime di base, l'alluminio e le leghe di alluminio sono ampiamente utilizzati in vari settori industriali.

Se state prendendo in considerazione la pressofusione di alluminio per i vostri prossimi progetti e volete conoscere questo processo in dettaglio, leggete la guida qui sotto.

Che cos'è la pressofusione di alluminio?

La pressofusione di alluminio produce componenti leggeri in alluminio con forme complesse e pareti sottili.

L'alluminio ha la capacità di resistere alla corrosione e offre anche un'elevata conducibilità elettrica e termica. È un processo che aiuta a mantenere la resistenza dei componenti in alluminio pressofuso anche a temperature estreme.

Il processo di pressofusione dell'alluminio è utilizzato da molto tempo e la prima pressofusione di alluminio è stata effettuata nel 1800 utilizzando l'iniezione a pressione. Nel 1849 è stata prodotta la prima macchina per la pressofusione. Tuttavia, era azionata manualmente.

Dopo 20 anni, lo sviluppo di questa stampante per la pressofusione è stato potenziato. Nel 1900 è stata utilizzata per diversi componenti prodotti in grandi volumi.

Come funziona?

Il processo di pressofusione dell'alluminio si svolge in più fasi, che sono le seguenti:

• Le barre di alluminio vengono prima riscaldate ad alte temperature fino alla fusione. Allo stesso tempo, viene utilizzata anche una camera fredda per evitare danni alla macchina.
• L'alluminio fuso viene tenuto in un crogiolo lontano dalla macchina di colata. Viene poi travasato dal pentolone nello stampo della macchina ad alta pressione.
• L'alluminio in forma liquida, dopo la fusione, viene iniettato nello stampo e, finché non si solidifica, viene lasciato a riposo.
• Le due metà dello stampo vengono separate per espellere il componente di alluminio solidificato.
• I componenti in alluminio pressofuso potrebbero richiedere un ulteriore processo di finitura per ottenere la finitura superficiale richiesta.

Vantaggi della pressofusione di alluminio

Il processo di pressofusione dell'alluminio viene scelto per i vantaggi che offre. Alcuni di questi vantaggi sono i seguenti:

• Questo processo produce componenti con una finitura superficiale liscia.
• Offre un'eccellente resistenza alla trazione e il costo delle materie prime è basso.
• La struttura molecolare dei componenti prodotti attraverso la pressofusione è solida e non si incrina sotto pressione.
• Offre una precisione dello spessore inferiore a 1,5.
• Offre una lunga durata e può produrre forme complesse.
• Le proprietà chimiche e meccaniche dei componenti in alluminio pressofuso sono eccellenti.

Tipi di alluminio utilizzati per la pressofusione

Le leghe di alluminio comunemente utilizzate per la pressofusione sono le seguenti:

• A390
• A380
• A413
• A360
• ADC-1
• ADC-12

La parte più importante della pressofusione di alluminio è la scelta della giusta lega di alluminio. La lega A390 offre un'eccellente resistenza all'usura ed è dura, ma è anche meno flessibile. Può essere utilizzata per i blocchi motore delle automobili.

L'A360, invece, ha un'eccellente resistenza alla corrosione e tenuta alla pressione. Quando sono in forma fusa, sono altamente fluidi e sono stati scelti per le coppe dell'olio delle automobili, le scatole di comunicazione 5G, ecc.

La lega A380 ha proprietà di fusione senza saldature e può essere utilizzata per mobili per la casa e utensili elettrici.

Opzioni di finitura superficiale per l'alluminio pressofuso

L'alluminio pressofuso può essere trattato con vari processi di finitura superficiale, tra cui i seguenti:

Anodizzazione

Anodizzazione è un processo economicamente vantaggioso che migliora la resistenza alla corrosione dei componenti prodotti con la pressofusione di alluminio. Migliora anche la durata dei componenti e aggiunge uno strato protettivo non conduttivo.

L'anodizzazione dell'alluminio viene utilizzata per creare uno strato di ossido che lo rende non conduttivo. È quindi adatta per le applicazioni in cui non è necessaria la conduttività elettrica.

Rivestimento in polvere

La verniciatura a polvere è uno dei processi più diffusi per la finitura della superficie dei componenti in alluminio prodotti mediante pressofusione.

Questo processo è condotto in condizioni di alta temperatura e migliora la resistenza ai graffi dei componenti. Questo processo consente di ottenere diverse finiture lucide, texture e colori sui componenti.

Film chimico

Il film chimico viene applicato con vari metodi, come l'immersione del componente, la spazzolatura o la spruzzatura. Offre un'elevata conducibilità elettrica ai componenti in alluminio pressofuso.

Applicazioni dei pezzi fusi in alluminio

I componenti in alluminio pressofuso sono ampiamente utilizzati in molte applicazioni, alcune delle quali sono le seguenti:

Costruzione

Nell'industria delle costruzioni, la pressofusione di alluminio aiuta a produrre telai per finestre e strutture del tetto. È molto utilizzata negli edifici commerciali e nei ponti.

Automobile

Le leghe di alluminio hanno un'elevata resistenza e un peso ridotto, che le rende efficienti dal punto di vista dei consumi quando vengono utilizzate nei veicoli. Per questo motivo, il industria automobilistica utilizza queste leghe in varie applicazioni, dalle parti della carrozzeria al motore dell'auto.

Industria elettronica

L'alluminio svolge un ruolo fondamentale nella produzione di componenti elettronici innovativi. Questi componenti elettronici sono prodotti utilizzando alluminio pressofuso, che può essere utilizzato negli alloggiamenti delle reti 5G e negli smartphone.

Mobili

L'industria del mobile utilizza l'alluminio per la sua elevata resistenza, il peso ridotto e la capacità di resistere alla corrosione. I componenti sono a basso costo e, pertanto, possono essere facilmente utilizzati per la produzione di mobili a prezzi accessibili.

Sedie, serrature, pomelli e altri accessori dell'industria del mobile sono prodotti con componenti in alluminio pressofuso.

Fattori da considerare nella progettazione di parti in pressofusione di alluminio

Quando si progettano componenti utilizzando il processo di fusione dell'alluminio, alcuni dei fattori da considerare sono i seguenti:

Progettazione dello stampo

La progettazione dello stampo deve essere perfetta ed efficiente, in modo che la parti in alluminio perfettamente. Lo stampo ha una linea di demarcazione che lo divide in due metà, e di questo bisogna tenere conto quando si creano i componenti.

Posizione del punto di iniezione

Quando l'alluminio fuso viene iniettato nello stampo, il punto di iniezione deve essere considerato con attenzione. Deve essere versato con precisione, assicurandosi che riempia la proprietà della cavità, perché a volte la solidificazione del metallo avviene molto rapidamente, portando a una struttura non uniforme.

Spessore della parete

Anche lo spessore del componente a parete è molto importante da considerare. È importante scegliere uno spessore consistente che garantisca l'uniformità del componente.

Conclusione

La guida di cui sopra contiene tutti i dettagli importanti relativi alla pressofusione di alluminio. Ora potete iniziare il vostro progetto tenendo conto di tutti questi aspetti e di come potete ottenere un componente in alluminio senza giunture.

Avviate i vostri prototipi e parti personalizzate in pressofusione di alluminio con DEK

Se state cercando aiuto per il vostro progetto di pressofusione di alluminio, noi di DEK può assistervi. Abbiamo anni di esperienza nella produzione di componenti in alluminio con processi di pressofusione.

Ci assicuriamo inoltre di fornirvi componenti personalizzati in base alle vostre specifiche. Quindi, contattateci oggi stesso e aiutateci a soddisfare i vostri progetti.

Elastomers of different types are used in manufacturing a wide range of components. Sometimes, they are also used for making prototypes.

If you are looking forward to learning about elastomer prototyping, the guide below is the key to the details.

What is Elastomer?

Elastomers are polymers which offer elasticity and viscosity.

Elastomer molecules can be joined together with the help of weak intermolecular forces that offer high yield strength and low Young's modulus.

Elastomers have the ability to gain their actual shape again after they have been stretched.

Types of Elastomer

There are two types of elastomers, and each type has its properties, as discussed below.

Saturated Elastomer

Saturated elastomers offer stability against ozone, radiation, heat and oxygen. These are not curable by sulfur vulcanization and have less reactivity.

Silicone and polyacrylic rubbers are the types of saturated elastomers.

Unsaturated Elastomer

Unsaturated elastomers are capable of being cured with the process of sulfur vulcanisation. The types of unsaturated elastomers are composed of natural polyisoprene and butyl rubber.

Methods to Produce Elastomeric Prototypes

There are different methods which can be used to produce elastomer prototypes, and these are as follows:

Fresatura CNC

Fresatura CNC is a process in which the software instructs tools of a CNC machine to shape and cut the elastomers.

The nature of elastomers is highly flexible, and this requires a lot of care during the machining process.

It is very important to avoid deformation by choosing the right speed of cutting tools and cooling methods.

The process of CNC milling is suitable for such prototypes of elastomers that need high accuracy, complex geometries, and intricate details.

It is usually opted for low-volume production of elastomer components.

Stampaggio a iniezione

Stampaggio a iniezione also helps manufacture elastomer prototypes in larger quantities. The elastomers are melted and injected into the mold, which has already been manufactured beforehand.

Once the molten elastomer has cooled down and solidified, it is demolded.

The process of injection molding can be repeated multiple times to manufacture more components of the same design.

It is very easy to manufacture prototypes of different elastomers using injection molding. The cost of mold, however, is high, and hence it is suitable for high volume production.

Stampa 3D

Stampa 3D deposits the material layer by layer to create a 3D component. Elastomer materials can also be used for manufacturing properties using 3D printing.

The process is flexible and offers quick changes with no expenses whenever needed in the design. Hence, this process is suitable for short runs and rapid prototyping.

It helps to create complex components and that too very quickly.

Design Considerations Of Elastomer Prototyping

When carrying out elastomer prototyping, there are a few design considerations that play a vital role, and these are as follows:

Materiale

When designing the prototype of elastomers, the right type of elastomer should be chosen for the application. The hardness, flexibility, strength and elongation are the aspects to consider.

Moreover, the compression ability of the material should be assessed to ensure it retains its original shape over time.

Spessore della parete

The thickness of the wall when manufacturing a prototype using an elastomer is important to maintain. When doing processes like injection molding, inconsistent thickness may lead to warping.

Hence, the thickness of the walls must be accurate. The thin walls lead to deformation and thick lead to improper filling.

Forme complesse

If the design has complex geometries, the elastomer prototyping can be challenging. It could lead to difficulty in ejecting the component and deformation.

In this case, the use of flexible inserts, draft angles and multi-part molds can be helpful.

Consider Shrinkage

Elastomers have a tendency to shrink once cured or molded. Hence, when designing a prototype using elastomers, consider the shrinkage.

Moreover, sometimes it gets very difficult to maintain tolerance with elastomers due to high flexibility; hence, setting realistic expectations is important.

Finitura superficiale

The surface finish of the elastomers plays a vital role in aesthetics as well as functionality.

Hence, it is important to have a smooth finish to help reduce friction. At the same time, a textured surface helps enhance grip.

The finishing of the prototypes also impacts the way elastomers interact with coatings. Hence, a finish should be chosen with the balance of performance and appearance in mind.

Start Prototyping Rubber Parts Efficiently with DEK

DEK offers to manufacture prototypes of rubber parts using different manufacturing processes.

We analyze the type of elastomers you want to use and choose the most relevant manufacturing process.

We have a team of expert engineers to offer their expertise in the manufacturing process of your components. So, get in touch with us to make the best of our prototyping services.

Conclusione

Understanding details about elastomers, processes involved in prototyping them, and their types is very crucial before you use them in your projects.

As you have read the guide above, every detail regarding the material must be clear allowing you to make informed decisions.

Aluminum is a widely used versatile material that has many grades. 7075 aluminum is also a very commonly opted grade, which has multiple applications and properties.

If you are looking to use 7075 aluminum in your projects and want to learn about it, read the guide below.

Che cos'è la lega di alluminio?

Aluminum alloys are metals that have aluminum as the prime metal, followed by other elements like tin, copper, magnesium, etc. The combination of these alloying elements with aluminum creates a new grade that modifies the structure and properties of the aluminum.

Composition of 7075 Aluminum

Aluminum 7075 is an lega di alluminio which has the following alloying elements:

• 87 to 91% of aluminum
• 5 to 6% of zinc
• 0-0.3% of manganese
• 1.2 to 2% of copper
• 2.1-2.9% of magnesium
• 0-0.5% iron
• 0.0-0.2% titanium
• 0.18-2% chromium
• 0.05-0.15% other types of elements

These elements, when added to aluminum in such small amounts, modify the properties of aluminum and make it suitable for different applications.

Properties of Aluminum 7075

Aluminum 7075 has the following properties:

• It has a density of 2.81 g/cm3 and a tensile strength of 228-572MPa; the yield strength is 103-503MPa.
• The modulus of elasticity ranges between 71.7 to 72.4 GPa, and Brinell hardness is 60-150.
• Shear modulus is 26.9-27 GPa, and elongation at break is 5% to 19%. The shear strength is 152-331 MPa, and the fatigue strength is up to 159 MPa.
• Aluminum 7075 offers a thermal conductivity of 130-173 W/mK and a specific heat capacity of 0.96KJ/kg°C.
• It has a melting point of 477°C.
• Aluminum 7075 has moderate corrosion resistance and high machinability, but it does not possess good weldability.

Advantages of Using Aluminum 7075

The advantages of opting for aluminum 7075 for the different projects are as follows:

• Aluminum 7075 offers a high strength-to-weight ratio.
• It works well under stress due to its high fatigue resistance. Therefore, applications where components are subjected to pressure may find aluminum 7075 suitable.
• Aluminum 7075 is highly machinable and can be opted for manufacturing components.
• Aluminum 7075 is not highly corrosion resistant, but some of its tempers, like T73, are suitable for marine and outdoor applications.
• It has a high modulus of elasticity and offers to be dimensionally stable.

Limitations of Aluminum 7075

Aluminum 7075 offers benefits but also has some limitations; some of these limitations are as follows:

• Aluminum 7075 has limited weldability and requires special techniques for welding, also, it has a tendency to crack during the process of welding.
• When compared to other aluminum grades, aluminum 7075 offers limited corrosion resistance and hence cannot be used in moisture-based environments unless treated.
• Aluminum alloys, apart from 7075, are quite affordable, whereas 7075 is very expensive and cannot be a suitable choice for budgeted projects.

Manufacturing Process of Aluminum 7075

The manufacturing process of aluminum 7075 involves different techniques, and the three most popular methods are given below.

Lavorazione CNC

CNC machining of 7075 aluminum uses a process of manufacturing controlled by software. A block of aluminum 7075 is used, and the cutting tools allow for the shaping and manufacturing of components.

Alluminio 7075 offers good machinability and tends to produce highly precise components. Applications that need aluminum 7075 components with tight tolerance opt for CNC machining.

Estrusione di alluminio

Il estrusione di alluminio process helps manufacture components from aluminum 7075. In this process, aluminum is heated and forced through a die so that components with the shape of the die are created.

The process is suitable for manufacturing multiple components with consistency and a long structure. This process offers components with improved mechanical properties and is cost-effective.

Pressofusione

Pressofusione process consists of injecting the aluminum 7075 in molten form into the molds using high pressure. Once the material has cooled down and solidified, it takes the shape of the mold.

The components manufactured through die casting offer consistent quality and are usually complex in shape.

Comparing Aluminum 7075 with Other Alloys

There are different alloys of aluminum, and comparisons of aluminum 7075 with those alloys are given below.

Aluminum 7075 vs. Aluminum 6061

Alluminio 6061 is also known as structure aluminum and is used in the construction industry. It is mostly opted for the purpose of extruding pipes, tubes, aluminum bars, etc. It is a versatile material and is opted for heat sinks and bicycle frames.

Compared to 7075, it has better corrosion resistance, high machinability, and is even weldable. However, the strength of 6061 is not as good as that of 7075.

Aluminum 7075 vs. Aluminum 2024

Alluminio 2024 is popular in aerospace applications and is opted for fuselages and wings of an aircraft. It is durable and is chosen for applications that need cyclic fatigue resistance.

7075 aluminum, on the other hand, is suitable for applications that have a high-strain and pressure environment. The two of these do not offer high weldability and even have the same machinability.

However, 7075 has better corrosion resistance, whereas 2024 has better workability.

Applicazioni dell'alluminio 7075

The applications of aluminum 7075 can be seen in different industries; some of these applications are as follows:

Aerospaziale: It is used in wings, fuselages, and structural components of aircraft due to its high strength-to-weight ratio.

Automobile: In the automobile industry, high-performance vehicles are mostly opted for to manufacture their components like chassis, driveshafts, and suspension parts.

Marina: Marine applications also use aluminum 7075 but require some additional coatings so that marine components made of aluminum 7075 resist corrosion.

Tools and Molds: Aluminum 7075 offers high strength, which is suitable for manufacturing tools, dies and molds for different manufacturing processes.

Conclusione

When selecting aluminum 7075 alloy, understanding its properties proves to be highly significant.

As you have gone through the guide, you must now know important details about aluminum 7075. If you need to have aluminum 7075 components manufactured with high accuracy, contact us at DEK.

Screws play a vital role in all types of projects, and you can have custom micro screws designed.

If you are planning to come up with a new project and want to learn about micro screws, the guide below has all the information regarding custom micro screw manufacturing.

What are Custom Micro Screws?

Custom screws are used in applications where standard screws cannot be used. These custom micro screws cater to the unique requirements of the project.

These screws are suitable for precision-oriented applications like aerospace, electronics, and medical. These industries cannot tolerate even a minor deviation.

These custom screws are made using versatile materials which cater the application requirements like corrosion resistance, weight considerations, and durability. These screws even ensure aesthetics and integrity.

Benefits of Custom Micro Screws

Custom micro screws are used widely in many applications; some of the benefits of custom micro screws are as follows:

• Custom micro screws are designed so that they meet the precise requirements of applications for which these are used.
• The custom micro screws can be optimized to meet the specific resistance to wear, corrosion and offer required strength.
• The custom micro screws can be made with versatile materials; these materials are chosen based on the environment they are opted for use. For instance, stainless steel micro screws can be chosen for an environment exposed to corrosion and high temperature.
• Certain industries need to fit very small components with perfection. Hence, these custom micro screws can be designed in the tiniest size to cater for precision.
• As they have the exact dimensions required for the application, the final product tends to have better performance and quality.

6 Drive Types for Custom Screws

The six drive types for custom screws which are commonly opted for are as follows:

Phillips Drive

Phillips drive has a cross-shaped slot, which is used for self-centering characteristics. The chances of slippage are very less in this type of screw. It is suitable for automated production lines and is also used in consumer electronics.

Torx Drive

Torx drive has a pattern of star shape. It has high torque transmission and less risk of cam-out. It is suitable for applications that require high precision, such as electronics and aerospace.

Slotted Drive

Slotted drives have a straight slot and have a very simple operation, but they can cam out. These are used in applications that need precise control of torque.

Tri-Wing Drive

Tri-wing drive has a slotted pattern in a triangular pattern and is used in applications that need tamper and stress resistance. It is commonly used in electronic devices that have a high control over access for adjustments and repairs.

Allen Drive (Hex Socket)

Allen drive has a hexagonal socket and works with an Allen key. It offers excellent torque and is used in automobile and machinery applications.

Robertson Drive (Square Recess)

Square recess offers cam-out resistance and a high capacity of torque. It is very commonly used in construction and woodworking as it is easy to use and holds strongly.

Custom Micro Screws Head Styles

The head style designed in custom screws requires balancing the screw fist and meets the specific application requirements. The head style should meet the space, torque, and ease of assembling requirements.

Moreover, the head style must have an aesthetic appearance in applications where they are visible. The main goal is to create a screw head that meets the design requirements, ease of use, and mechanical needs of the product.

Material Selection of Custom Micro Screws

The material of custom micro screws plays a vital role in performance and durability. Based on the environment it will be exposed to, the material is chosen for these screws. Some of the commonly adopted materials are as follows:

Metalli

The different types of metals are commonly chosen for the micro screws; some of these metals are as follows:

• Stainless steel is a highly corrosion-resistant material that is suitable for applications that are exposed to moisture or outdoors.
• Aluminum is a lightweight material and is suitable for applications that are weight-sensitive.
• Brass is also resistant to corrosion and offers moderate strength. It is heavier than aluminum but not as heavy as steel. It is chosen for decorative purposes.

Plastica

• Nylon is suitable for insulation and also is lightweight. It offers chemical and corrosion resistance and works well in light-duty applications.
• Polycarbonate has excellent resistance against impact and corrosion and is used in applications that need transparency and lightweight screws.
• PVC is highly corrosion-resistant and soft and is used in plumbing applications as it resists chemicals and water.
• ABS is extremely strong and lightweight and, hence, can work in electronics and automobile applications.

The Importance of Precision in Size and Tolerance

The custom micro screws need to be highly precise and tolerant for the sizes; a minor deviation may lead to issues with their performance. Hence, the tolerance of these screws must be very carefully adjusted.

These custom micro screws are mostly used in sensitive applications like aerospace, electronics, and medicine.

The manufacturing process for these screws needs to be highly precise and consistent. The accuracy of these screws offers successful projects as they work with effectiveness.

Threading and its Impact on Micro Applications

The threading of custom micro screws is also vital for their functionality as it determines their fitting into different applications. The aspects like depth, pitch, and influence of profile are very important; they reflect the way the screw interacts with the material.

Industries like medical and microelectronics are highly precise industries, and they prefer fine threads for the micro screws.

These screws ensure a very strong grip and also secure the materials very well. The design of the thread also impacts the way screws can be fixed and removed.

The load distribution is also affected by the threading of the screw, and it impacts the wear resistance, durability, and strength in applications where they are used repetitively.

Manufacturing Method of Custom Micro Screw

The manufacturing process of custom micro screws varies based on the material and applications. Some of the commonly opted micro screw manufacturing processes are as follows:

Lavorazione CNC

Lavorazione CNC is one of the most precision-oriented methods which helps to manufacture micro screws. The process works using CNC-controlled machines, which have highly accurate and detailed manufacturing capabilities.

The block of material is carved to manufacture the micro screw based on the custom design. This process helps manufacture micro screws with tight tolerance, and industries like aerospace and medical use it.

Swiss Screw Machining

Swiss screw machining or Swiss turning is a machining process that helps manufacture micro screws with the help of a lathe.

The workpiece is fixed and rotated, allowing the lathe to cut the workpiece and derive the micro screw. The micro screws that have complex geometry are usually manufactured through this process.

Arrotolamento del filo

The thread-rolling process creates threads on the micro screws. The process starts by pressing a die that is shaped on the workpiece and rotates. The process helps to create strong threads and offers fatigue resistance.

Cold Heading

The process of cold heading involves a metal wire which is cut into the given length, and then a screw shape is formed at room temperature.

This process is suitable for producing custom micro screws in mass volume, and it offers strength to these screws with work hardening. These micro screws are mostly used in the automobile industry.

Micro Injection Molding

The process of micro injection molding helps in producing micro screws that are manufactured using plastics.

The process of injection molding works by injecting molten plastic into the mold, which is left for solidification. The process is suitable for manufacturing plastic screws which are highly precise and suitable for the electronic industry.

Applications of Custom Micro Screws

Custom micro screws are used in many industries, and some of their applications are as follows:

Elettronica

Electronics are of varied sizes, and each of them requires different screws to fix components. Microelectronics usually need micro screws as they can easily align the components.

Some of the devices like mobiles, tablets, circuit boards, and smartwatches are assembled using micro screws.

Medico

Micro screws are used in the medical industry for assembling surgical tools, orthopedic implants, dental implants, and even in diagnostic equipment. The precision of these micro screws tends to cater to the industria medica with highly accurate fixation.

Aerospaziale

The aerospace industry requires custom micro screws, which are strong, lightweight, and precise; aircraft components and satellites tend to have these.

Automobile

Micro screws help in fastening electronic systems and sensors of the engine. They are especially used in motorcycles, racing cars, and electric vehicles, as precision is significant here.

How to Balance Cost and Quality?

Custom micro screw selection is successful when there is a balance between quality and cost. The low-cost screw helps save upfront costs, but in the longer run, the high cost of maintenance and failure risk is present.

Whereas, when you invest in high-quality screws, the cost is high, but the performance and durability are top-notch.

The key to success in these custom micro screws is to choose the screws with moderate cost and also meet quality standards.

Start Your Custom Micro Screw Project with DEK

If you are looking for high-quality and cost-effective custom micro screws which offer precision, you can consider DEK. We offer multiple methods of manufacturing these micro screws– customized according to your specifications and precision.

So, get in touch with us today and specify your application requirements for the custom micro screws.

Conclusione

The significance of custom micro screws in multiple applications plays a vital role. The guide above must have given you an insight into the types of micro screws and manufacturing processes.

Understanding all these details helps you make informed decisions regarding micro screw selection for your applications.

CNC machining is a common process that is done to manufacture components for various industries. It is compatible with almost all types of materials, including ceramics.

If you want to learn about ceramic CNC machining, the guide below can offer you a lot of details. So let's read.

What is Ceramic CNC Machining?

Ceramic CNC machining is a process in which CNC machining tools are used to remove material from the ceramic workpiece.

The removal of the material helps to shape the ceramic components. The machine works with tools that function according to the instructions in the CAD software.

Different types of ceramic materials are opted to create components that have accuracy and tight tolerance for versatile industries.

What are the Properties of Ceramic?

Ceramic is a non-metal material and has various properties that make it suitable for different uses. Some of these properties of ceramics are as follows:

• Ceramics are very hard and, hence, resistant to scratching and wear. Therefore, they are suitable for opting for protective coating, cutting tools, and abrasives.
• Ceramics are brittle, and they can break when subjected to pressure. However, they can withstand certain forces.
• Ceramics have a high melting point, which makes them suitable for applications such as heat shields and furnace linings.
• Ceramics are poor conductors of heat, and hence, they can be opted for applications like engine components and space shuttle tiles. They do not transfer heat easily.
• Ceramics are resistant to attacks of chemicals, oxidation, and even corrosion. Hence, it can be suitable for harsh environments.

CNC Machining Operations for Ceramics

CNC machining operations that are mostly opted for manufacturing ceramic components are discussed below:

Fresatura CNC

Il CNC milling process shapes ceramic components by removing the ceramic material from the workpiece. The cutting tool spins and carves a design on the ceramic workpiece.

This process helps create intricate shapes and consistent cuts. The ceramic components manufactured through this process have a very smooth surface finish.

Core Drilling

Core drilling is also a drilling technique that extracts the material from a piece of ceramic in the form of a cylindrical section. This process helps to drill precise holes and creates a pathway for mounting components or electrical wiring.

CNC machining directs the cutter in a rotating form to create a hole of the exact size and position.

Rettifica di superficie

Surface grinding uses a grinding wheel to finish the surface of the ceramic component. This process is used to produce components with precision and smooth finishes. Surface grinding is used for ceramic parts that are flat or have parallel surfaces.

Types of Ceramics for CNC Machining

CNC machining is carried out on a wide variety of ceramics, and some of these types are as follows:

Alumina Ceramic

Alumina ceramic is brittle and hard, so it needs slow rates of feed followed by precise tooling.

It is used in manufacturing electrical insulators, wear-resistant components, and implants for the medical field using CNC machining. They are known for their corrosion resistance and tensile strength.

Boron Nitride

Boron nitride is very challenging when it comes to machining, and it can be machined using highly advanced tools. It has excellent insulation and thermal conductivity. Hence, it is used in insulation and semiconductor applications.

Silicon Carbide Ceramic

It is very hard, and when machining it, the need for coolant and diamond tools is significant so that tool wear can be prevented. It is mostly used for manufacturing heat exchangers, bearings, and semiconductor applications. It offers excellent thermal stability and hardness.

Zirconia Ceramic

Zirconia ceramic is tough and can be machined using highly controlled machined environments with diamond tooling. It is used to manufacture oxygen sensors, cutting tools, and dental implants. It offers excellent wear resistance, toughness, and chemical stability.

Steatite Ceramic

It is soft and, hence, easy to machine. It is also known for its affordability and seamless electrical properties. It is used in capacitors, electrical insulations, etc.

Quartz

Quartz is brittle and can easily crack. Therefore, it needs very careful handling during the machining process. It is transparent and has excellent electrical conductivity. It is mostly opted for manufacturing piezoelectric sensors, optical devices, and semiconductor applications.

Cordierite Ceramic

It is very easy to machine and offers excellent thermal shock resistance. It is mostly used in applications like kiln furniture, catalytic converters, and thermal barriers.

Macor

Macor is highly machinable and doesn't need any specialized tools. It offers electrical insulation and is chosen for medical components, vacuum chambers, and electrical components.

Vetro

Glass is very sensitive and brittle, so it requires careful machining using diamond tooling. It is known for its transparency and high optical properties. It is used mostly for fiber optics, display screens, and optical lenses.

Grafite

Graphite is very soft, has an excellent lubrication nature, and has thermal conductivity. It is used in manufacturing lubricants, brake linings, electrodes, and crucibles.

Mycalex

It is brittle but can still be machined through carbide tools. The machining parameters should be carefully set. It is used in high-temperature environments as it offers electrical insulation.

Benefits of Ceramic CNC Machining

Ceramic components are CNC machined as they offer excellent benefits when combined with this process. Some of these benefits of ceramic CNC machining are as follows:

• Ceramic CNC machining is a versatile process that can manufacture ceramic components accurately and precisely.
• Ceramic CNC machining is quite cost-effective when compared to other methods like waterjet cutting and laser cutting. It has a high rate of production and lower operation costs.
• CNC machining allows immediate adjustments and hence can cater to the scalability of ceramic CNC machined components.
• Ceramic CNC machining is a precise process and can handle the brittleness of ceramics.
• The process of CNC machining for ceramics helps create components that have complex geometries.
• Ceramic components manufactured using CNC machining have tight tolerance, as required by most applications.

Challenges in Ceramic CNC Machining

Although ceramic CNC machining has various benefits at the same time, it also has some challenges, which are as follows:

• Ceramics are brittle as they have crystalline structures and, hence, are prone to cracking during the process of machining.
• Ceramic materials are at risk when machined as too much pressure may lead to chipping off and cracking the components.
• Some types of ceramics are very hard and cannot be machined using standard tools. They either need highly advanced tools, or they lead to wear and tear of the tools. It ends up increasing the cost of tooling.

Applications of Ceramic CNC Machining

Ceramics are commonly used, and the applications of CNC machining ceramics can be observed in various industries, and some of these are as follows:

Engineering Ceramics

CNC-machined ceramic components are used in engineering ceramics as they can withstand high pressure and temperature. Hence, components like combustion liners, heat exchangers, and turbine parts are manufactured using it.

The process of CNC machining offers precision, and hence, during production, the risk of cracking is also reduced.

Healthcare Sector

Ceramic materials are suitable for medical applications due to their biocompatibility. They can easily be CNC machined and used in joint replacements and implants with the high precision they offer.

Industria aerospaziale

Il industria aerospaziale uses CNC machined ceramic components due to their lightweight and intricate nature. The components for aerospace, like heat shields, jet engine nozzles, and turbine blades, are manufactured using it.

CNC machining makes these components precise, and due to their lightweight, they offer fuel efficiency.

Industria elettronica

CNC machining ceramics helps manufacture various components for the electronics industry. The components like semiconductor substrates and circuit boards need high dielectric strength. Hence, the precision CNC machining is used to manufacture these components.

Tips When Designing and CNC Machining Ceramic

When designing and CNC machining ceramic components, some of the tips that ensure effective machining process and optimal results are as follows:

• It is very important to choose the right type of ceramic. Factors like wear resistance, hardness, and thermal stability are important.
• Carbide-based tools and diamond-based tools are the two types of tools that are suitable for CNC machining ceramics. They can handle extreme hardness and hence make the machining process efficient.
• Machining parameters like feed rate, depth of the cut, and cutting speed are very important to manage. They can help reduce wear and ensure optimal performance.
• The use of coolant is significant when machining ceramics as it helps to control the heat and also ensures that the component is free from damage.

Start Your CNC Machining Ceramic Project with DEK

If you are looking forward to having custom ceramic CNC machining components designed and manufactured for your products, you can give us a chance to serve you.

Noi di DEK sign a nondisclosure agreement to keep your business information and designs confidential.

Moreover, we have an experienced team of engineers with highly advanced CNC machines that provide seamless components.

Conclusione

Ceramic is a very versatile material and has many types. Each type has unique properties. You must have learned everything about ceramic and the CNC machining process of ceramic, which offers you the ability to make informed decisions for your projects.

La lavorazione del molibdeno è un compito impegnativo a causa della natura del materiale. Richiede processi specializzati e diverse tecniche CNC per ottenere i risultati desiderati.

Se siete interessati a conoscere il processo di lavorazione del molibdeno e gli aspetti importanti che dovete conoscere. Leggete la guida qui sotto.

Conoscere il molibdeno metallico

Il molibdeno non è molto utilizzato come l'acciaio e l'alluminio. È un metallo refrattario ed è un buon conduttore di elettricità. Il punto di fusione del molibdeno è di 2623° C.

Questo materiale offre anche un'elevata resistenza alla corrosione e un basso coefficiente di espansione termica. Ha un'elevata resistenza e può essere utilizzato in applicazioni ad alta sollecitazione.

Tecniche di lavorazione del molibdeno

La lavorazione del molibdeno utilizza diverse tecniche CNC per ottenere i dettagli e le forme desiderate nei componenti in molibdeno. Alcune delle tecniche adottate per la lavorazione del molibdeno sono le seguenti:

Fresatura CNC

Fresatura CNC utilizza utensili da taglio che ruotano e tagliano il materiale dal pezzo. Questo processo consente di creare componenti con caratteristiche dettagliate e geometrie complesse. Il materiale molibdeno è duro e quindi richiede utensili da taglio in carburo per il processo di fresatura.

Il processo di fresatura del molibdeno viene eseguito a bassa velocità per ridurre l'accumulo di calore. Inoltre, la velocità di avanzamento deve essere mantenuta in modo ottimale per evitare l'usura degli utensili.

Durante il processo di fresatura, viene applicato un refrigerante per evitare il surriscaldamento e migliorare la durata dell'utensile.

Tornitura CNC

Tornitura CNC aiuta a produrre componenti di molibdeno di forma cilindrica. Durante il processo di tornitura, il pezzo ruota e l'utensile rimane in posizione.

Il sistema aiuta a mantenere un controllo preciso sul processo di taglio e gli utensili in metallo duro sono scelti per garantire tagli puliti.

Durante il processo di tornitura CNC del molibdeno, i sistemi di raffreddamento vengono messi in atto in modo da evitare il calore. Il percorso utensile e la velocità di taglio sono ottimizzati per ottenere una finitura superficiale omogenea.

Foratura CNC

Foratura CNC utilizza punte in acciaio ad alta velocità che consentono di creare fori di diverse profondità e dimensioni. Il processo di foratura CNC consente di forare lungo più assi, in modo da ottenere fori precisi e complessi.

Sfide nella lavorazione del molibdeno

Il molibdeno ha proprietà impressionanti, ma a volte la durezza e la resistenza di questo materiale si rivelano una sfida per il macchinista. Alcune sfide affrontate durante la lavorazione del molibdeno sono le seguenti:

Fragilità

Il molibdeno presenta una durezza senza soluzione di continuità e, pertanto, a volte il suo taglio può rappresentare una sfida. I metodi tradizionali di lavorazione, quando vengono utilizzati per tagliare il molibdeno, rendono difficile ottenere tagli puliti.

A volte, il taglio del molibdeno può essere estremamente impegnativo e portare all'usura degli utensili. La natura fragile del molibdeno provoca la produzione di trucioli, con conseguenti difficoltà di lavorazione.

Il problema della fragilità può essere risolto utilizzando utensili da taglio in metallo duro che aiutano a tagliare efficacemente il molibdeno. Inoltre, gli utensili con taglienti affilati aiutano a tagliare bordi netti senza produzione di trucioli.

Alto punto di fusione

Il molibdeno ha un punto di fusione elevato, che può favorire alcune applicazioni, ma allo stesso tempo la lavorazione a causa dei punti di fusione elevati può rappresentare una sfida. I metodi tradizionali di raffreddamento durante la lavorazione possono essere insufficienti e la finitura superficiale può essere compromessa.

Per affrontare il problema dell'elevato punto di fusione durante la lavorazione, è necessario optare per refrigeranti ad alte prestazioni. I refrigeranti miscibili con l'acqua si rivelano utili per ridurre il calore.

È inoltre possibile utilizzare una piccola quantità di lubrificante, che aiuta a ridurre al minimo il consumo di refrigerante, e scegliere utensili realizzati con materiali resistenti al calore. Tali utensili sono composti da leghe a base di cobalto, che rimangono intatte alle alte temperature.

Gradi comuni di lega di molibdeno nella lavorazione meccanica

Il molibdeno ha molteplici applicazioni e diversi gradi. Ogni grado ha le sue proprietà e la sua idoneità per un'applicazione. Alcuni dei gradi più comuni per la lavorazione sono i seguenti:

Molibdeno puro

Il molibdeno puro è costituito da una quantità minima di impurità e da una quantità maggiore di molibdeno. Ha un'eccellente resistenza e non si corrode; offre inoltre un elevato punto di fusione.

È adatto per la produzione di componenti di forni, elettrodi per la saldatura a fascio elettronico e crogioli.

Lega di molibdeno TZM

Molibdeno TZM ha un'elevata resistenza e tenacità. È composto da leghe come il tantalio e lo zirconio. L'aggiunta di questi due elementi garantisce un miglioramento della resistenza al creep del molibdeno.

È adatto per applicazioni che prevedono contatti elettrici ad alta temperatura, ugelli di motori per razzi e pale di turbine a gas.

Lega di molibdeno-lantanio

La lega molibdeno-lantanio contribuisce a ridurre l'usura degli utensili di lavorazione. Inoltre, migliora la ricristallizzazione del molibdeno e quindi viene scelta per i componenti che richiedono precisione. Viene scelta per i componenti aerospaziali e per le applicazioni dei semiconduttori.

Finiture superficiali per parti lavorate in molibdeno

Una volta completato il processo di lavorazione del molibdeno, i componenti possono richiedere ulteriori finiture. Alcune di queste opzioni per la finitura superficiale sono le seguenti:

Lucidatura

Il processo di lucidatura prevede l'uso di abrasivi che aiutano a levigare le superfici dei componenti in molibdeno. Inoltre, contribuisce a ridurre la rugosità e a migliorare la finitura della superficie dei pezzi.

È adatto per le parti che richiedono un'elevata lucentezza e migliora la funzionalità dei componenti.

Sabbiatura

La sabbiatura utilizza particelle abrasive per sabbiare la superficie al fine di creare una struttura per pulirla. Questo processo crea uniformità e rimuove anche i contaminanti dalla superficie del molibdeno. Questo processo prepara la superficie per ulteriori processi di finitura.

Passivazione

La passivazione tratta la superficie del molibdeno con una soluzione acida che ne aumenta la resistenza alla corrosione. Il processo di passivazione rimuove anche i contaminanti e crea uno strato di ossido passivo.

Questo strato protegge il componente dall'ossidazione e ne aumenta la durata se sottoposto a un ambiente corrosivo.

Cromatura dura

La cromatura dura crea uno strato di cromo sulla superficie dei componenti in molibdeno. Questo strato conferisce al componente una maggiore durezza e resistenza alla corrosione e all'usura. La cromatura dura rende la superficie più resistente.

Rivestimento

Il rivestimento si avvale di metodi come CVD o PVS; lo strato di rivestimento migliora la protezione del componente, aggiungendo resistenza all'usura e alla corrosione. Migliora le prestazioni dei componenti e li aiuta a funzionare anche in ambienti difficili.

Applicazioni della lavorazione CNC del molibdeno

I componenti lavorati in molibdeno sono ampiamente utilizzati per soddisfare le esigenze di diversi settori industriali e alcune delle loro applicazioni sono illustrate di seguito:

Apparecchiature ad alta temperatura: Il molibdeno è molto adatto per i componenti dei forni e degli scambiatori di calore, in quanto è in grado di resistere al calore estremo.

Trattamento chimico: È altamente resistente alla corrosione e per questo viene scelto dagli impianti chimici per la produzione di raccordi, tubi e valvole.

Componenti resistenti all'usura: Il molibdeno è duro e quindi viene utilizzato nei macchinari per la frantumazione, nelle attrezzature minerarie e negli strumenti per la perforazione petrolifera.

Produzione di semiconduttori: La resistenza chimica e la purezza del molibdeno lo rendono adatto alle applicazioni dei semiconduttori.

Lame per turbine a gas: Ha un'elevata resistenza al calore e i componenti in molibdeno lavorati sono adatti ai motori a reazione.

Sistemi d'arma: Offre resistenza all'usura e affidabilità quando viene scelto per i sistemi d'arma.

Avviate il vostro progetto di lavorazione CNC del molibdeno con DEK

Come già detto, il processo di lavorazione del molibdeno può essere impegnativo. Se anche voi desiderate avere servizi di lavorazione del molibdeno per le vostre applicazioni, contattateci.

Noi di DEK assicuriamo componenti in molibdeno di alta qualità, precisi e convenienti. Firmiamo anche un NDA con voi; potete stare tranquilli sulla riservatezza delle informazioni commerciali.

Conclusione

Il processo di lavorazione del molibdeno presenta un'ampia gamma di applicazioni e proprietà, che lo rendono estremamente adatto alla lavorazione CNC. Tuttavia, esistono alcune sfide che possono essere gestite con efficienza.

La lavorazione CNC è un processo molto comunemente scelto per la produzione di componenti utilizzati in applicazioni di materiali versatili.

Tuttavia, l'investimento in attrezzature per la lavorazione CNC e la formazione del personale potrebbero rappresentare un ulteriore onere. Per evitare tali investimenti, molte aziende cercano di esternalizzare la lavorazione CNC.

Se volete sapere tutto sull'outsourcing della lavorazione CNC, potete consultare questa guida.

Che cos'è l'outsourcing della lavorazione CNC di precisione?

L'outsourcing della lavorazione CNC è una soluzione che prevede la collaborazione con fornitori esterni di servizi di lavorazione CNC. Questi dispongono di macchine, personale qualificato e competenze per la produzione dei componenti.

I componenti prodotti con la lavorazione CNC hanno tolleranze strette e un'elevata precisione. Scegliendo di esternalizzare i processi di lavorazione CNC, potrete usufruire di componenti efficienti dal punto di vista dei costi senza alcun investimento interno.

Vantaggi dell'outsourcing della lavorazione CNC

L'outsourcing della lavorazione CNC offre ampi vantaggi, alcuni dei quali sono i seguenti:

Flessibilità

I processi di lavorazione CNC, se esternalizzati, vi offrono flessibilità. Potete sempre scalare il livello di produzione per soddisfare le vostre esigenze e la domanda del mercato. Potete adattare la fornitura di componenti in base alla domanda.

Alta precisione

I componenti CNC sono componenti altamente precisi, impossibili da ottenere con metodi di produzione manuali.

Il processo di lavorazione CNC, se affidato all'esterno, consente di avere componenti altamente precisi per diverse applicazioni.

Controllo di alta qualità

La qualità è un aspetto fondamentale per i componenti realizzati con la lavorazione CNC. Il processo è automatizzato e quindi i risultati sono ottimali.

Tuttavia, il fornitore di servizi garantisce anche la coerenza della qualità dell'intero lotto di componenti.

Piccolo investimento

La redditività delle aziende dipende in larga misura dal controllo dei costi. Quando si acquista una macchina CNC per conto proprio, è necessario un investimento elevato.

Tuttavia, in outsourcingIl cliente paga per i componenti acquistati in outsourcing. Pertanto, se gestite una piccola impresa, potete trarre vantaggio dall'outsourcing.

Non è necessario effettuare un investimento elevato e si può gestire il proprio capitale in modo efficiente.

Competenze specialistiche

I fornitori di servizi di lavorazione CNC sono esperti e possiedono le competenze e l'esperienza necessarie per produrre componenti con la lavorazione CNC.

Pertanto, se li prendete in considerazione per affidare all'esterno i vostri componenti lavorati a CNC, potete essere certi di ottenere risultati di alta qualità.

Rischio ridotto al minimo

Il processo di lavorazione comporta anche la possibilità di errori, con conseguente spreco di materiale.

Quando esternalizzate la lavorazione CNC dei componenti, potete proteggervi dal rischio di errori e sprechi.

Tempi rapidi di esecuzione

L'outsourcing della lavorazione CNC vi aiuta a produrre rapidamente. I componenti vengono prodotti rapidamente e quindi potete lanciare i vostri prodotti molto velocemente.

Sfide dell'outsourcing della lavorazione CNC

L'esternalizzazione della lavorazione CNC comporta ampi vantaggi, ma allo stesso tempo si devono affrontare alcune sfide. Alcune di queste sfide sono le seguenti:

Barriere alla comunicazione

Mantenere un coordinamento e una comunicazione efficaci con i fornitori di servizi di lavorazione CNC potrebbe essere una sfida.

Potrebbero esserci barriere linguistiche, e seguire il programma di produzione, i requisiti di qualità e i tempi di consegna può essere difficile.

Rischio di diritti intellettuali

Quando esternalizzate la lavorazione CNC dei vostri componenti, dovete condividere con loro i vostri progetti, il che può costituire un problema.

Alcuni dei disegni potrebbero essere personalizzati, che si desidera mantenere riservati. In questo caso è necessario firmare accordi per proteggere la proprietà intellettuale dell'azienda.

Controllo qualità

Quando si esternalizza la produzione di componenti CNC, il produttore dispone di attrezzature molto avanzate, ma il controllo della qualità può comunque rappresentare una sfida.

Prima di affidare il progetto dei componenti di lavorazione CNC a un fornitore, assicuratevi di conoscere il suo sistema di controllo qualità.

Rischio della catena di fornitura

Quando ci si affida a un fornitore per i componenti lavorati CNC, si deve affrontare il rischio della catena di fornitura. Vari fattori esterni, come questioni politiche, meteorologiche e altre circostanze impreviste, possono avere un impatto sulla catena di fornitura.

Costoso a lungo termine

Il costo dei componenti può essere inferiore nel breve periodo o quando le quantità sono limitate. Tuttavia, nel lungo periodo, il costo dell'outsourcing può essere molto elevato, soprattutto quando si deve produrre un gran numero di componenti.

Industrie comuni che utilizzano l'outsourcing della lavorazione CNC

Molte industrie esternalizzano la lavorazione CNC a fornitori di servizi, e alcune di queste industrie sono le seguenti:

Aerospaziale

L'industria aerospaziale richiede componenti realizzati con materiali versatili ma resistenti e di elevata precisione. La lavorazione CNC garantisce la coerenza e l'esatta tolleranza.

Quindi, componenti aerospaziali come le parti dei motori, le pale delle turbine e i componenti strutturali sono solitamente affidati all'esterno.

Industria automobilistica

Anche l'industria automobilistica utilizza la lavorazione CNC e produce componenti versatili. Questi componenti consistono in prototipi, componenti del motore e alloggiamenti della trasmissione.

Le aziende automobilistiche possono mantenere un elevato standard di qualità e risparmiare sui costi di produzione esternalizzando questi componenti.

Industria medica

Il settore sanitario richiede un'ampia gamma di componenti lavorati a CNC, poiché l'accuratezza e la precisione sono fondamentali in queste applicazioni.

La lavorazione CNC consente la produzione di strumenti medici come impianti, strumenti chirurgici e componenti di apparecchiature mediche. Per questo motivo, l'industria medica esternalizza la produzione di questi componenti.

Elettronica

I componenti elettronici come i connettori, le custodie e i dissipatori di calore richiedono tolleranze strette e progetti precisi, per cui vengono lavorati con macchine CNC. I produttori di elettronica affidano il processo di produzione di questi componenti ai fornitori.

Come scegliere il giusto partner per i servizi di lavorazione CNC in outsourcing?

Per produrre componenti accurati, è molto importante scegliere il giusto fornitore di servizi di outsourcing. Alcuni aspetti da considerare a questo proposito sono i seguenti:

• Il fornitore di servizi di lavorazione CNC scelto deve offrire tutti i tipi di servizi di lavorazione CNC, tra cui tornitura CNC, foratura CNC, fresatura CNC e persino elettroerosione. Deve anche offrire la finitura superficiale in modo che i componenti siano pronti per l'uso.
• Il track record dei fornitori di servizi dà un'idea dei loro servizi e della loro qualità. Si può sempre prendere in considerazione la possibilità di controllare i loro progetti passati e i feedback dei clienti precedenti. Questo vi aiuta a valutare la loro affidabilità.
• I fornitori di lavorazioni CNC con cui intendete collaborare devono essere trasparenti e accessibili. Dovete essere in grado di comunicare liberamente con loro e di discutere le vostre esigenze; devono anche essere disposti a tenervi aggiornati.
• Il servizio di lavorazione CNC fornito a coloro che intendono esternalizzare i progetti di lavorazione CNC deve essere dotato di attrezzature avanzate. Il team di cui dispone deve inoltre possedere competenze ed esperienze rilevanti e deve anche essere in possesso di certificazioni.
• È molto importante scegliere un servizio di outsourcing per la lavorazione CNC che offra un buon rapporto qualità-prezzo. Il fornitore di servizi giusto vi offrirà componenti di alta qualità senza compromessi sulla qualità, sui tempi di consegna e sulla precisione dei componenti.

Iniziate il vostro progetto di outsourcing della lavorazione CNC con DEK

Se siete alla ricerca del fornitore di servizi giusto per il vostro progetto di lavorazione CNC, potete contattarci a DEK. Offriamo componenti lavorati a CNC di alta qualità e personalizzati in base alle vostre esigenze.

Disponiamo di un team di professionisti esperti che si dedicano alla produzione di pezzi accurati e precisi. Potete affidarvi a noi per i vostri progetti, poiché siamo disposti a firmare un NDA con voi per mantenere riservati i vostri progetti e i vostri dati aziendali.

Conclusione

L'esternalizzazione dei componenti CNC comporta ampi vantaggi: come azienda, potete concentrarvi su altre aree principali e far produrre i compensi per voi.

La guida di cui sopra deve avervi illuminato con tutti i dettagli essenziali sull'outsourcing della lavorazione CNC.

Titanium polishing is important as it enhances the surface finish of titanium components. It helps to remove most of the titanium material from the component to add smoothness.

If you want to learn what is titanium polishing, you can read this guide below.

What is Titanium Polishing?

The process of titanium polishing uses a polishing wax and buffing wheel, which helps reduce the roughness of components. This process enhances the appearance of the titanium component.

Once the component is machined, polishing gives additional coverage and protection to it with a better finish.

Polishing is also a process that allows you to exercise high control; you can, therefore, polish complex and small components of titanium with high precision.

How to Polish Titanium with A Mirror Finish?

The process of polishing titanium with a mirror finish has the following steps:

Cleaning and Degreasing

Titanium manufacturing may leave behind residue and grease on the component, which needs to be cleaned. You can clean it with the help of degreasing agents and then rinse the component well.

Once it is appropriately soaked in water, remove and dry it properly.

Process of Sanding

On the clean and dry titanium component, smoothen the component’s surface with the help of sandpaper. The process of sanding allows the oxidized layer on the surface to be removed. It even improves the metal adhesion for better results after polishing.

Process of Buffing

Buffing gives a mirror-like, shiny appearance to the titanium component. The surface is first cleaned with an alcohol-based cleanser. Once clean, the buffing wheel and metal polish are used to polish, and water is applied to control the heat.

Finishing Stage

After the buffing process, some marks may be left behind on the component. In order to remove these marks, a paint polish is applied on a clean towel, and the surface is rubbed.

A layer of sealant is also applied and left to dry. It achieves the final polished look with a shiny appearance.

Why is Titanium Polishing Important?

There are various reasons that make titanium polishing important, and some of these are as follows:

• The physical appearance of the titanium component is very crucial, along with its performance. Polishing the components enhances the physical look and improves its aesthetics. The surface polishing ensures that the required gloss is achieved on the component.
• The layer of polish on the titanium component enhances its corrosion resistance and wear resistance and even reduces friction.
• Titanium is a poor conductor of electricity. Adding a polished finish allows current to travel through the titanium component, making it conductive.
• The life span of titanium components increases when a layer of polish is added to their surface. It offers corrosion and wear resistance, which makes it durable.

Different Types of Titanium Surface Polishing

Different types of surface polishing options are available for titanium. Some of these are as follows:

Rough Polishing

Rough polishing can be achieved with an abrasive buffing wheel. The wheel has titanium wax polish and silicon oxide and works with minimal force. It is suitable for the round-off corners of components.

Medium Polishing

Medium polishing uses abrasive when made using polish wax and aluminum oxide. Rough polishing leaves behind a dull surface, which can be brightened and smoothed using medium polishing.

Fine Polishing

Fine polishing makes the component of titanium reflective. It uses a wax polish and a soft cotton buffing wheel. It creates a fine surface, and more pressure is exerted on it.

Mirror Polishing

Mirror polishing for titanium components offers a surface finish that looks like a mirror.

The process uses polished wax and a soft buffing wheel, which is made using cotton. This type of buffing wheel is capable of reaching the areas of the component that are difficult to access.

Methods of Polishing Titanium

There are different methods that can be opted for when it comes to polishing titanium, and these are as follows:

Mechanical Polishing

Mechanical polishing is a process in which either machine force or manual force is used to remove material from the surface of titanium. This process helps reduce imperfections on the surface and allows for smoothness.

The process consists of using a combination of coarse and finer grits to remove the material from titanium and achieve a polished finish.

Elettrolucidatura

Electropolishing uses electric current, which creates a chemical reaction leading to polishing the surface. It helps in removing the layer of titanium material and even works well with complex shapes.

The titanium part is submerged in a chemical bath, and the material is removed through anodic dissolution as the current passes.

Lucidatura chimica

The process of chemical polishing uses chemical solutions that help in polishing the titanium surface. The titanium part is immersed in a chemical bath, which has acids, and these remove the imperfections of the surface.

It is suitable for the complex and internal areas which are difficult to reach using other methods. It offers a uniform surface finish and is used in medical and aerospace applications.

Plasma Polishing

Plasma polishing is a process in which plasma jets are used. These help to remove the surface material and create a neatly finished surface.

The plasma jet ionizes the titanium and removes the material in a very controlled way. It is suitable for high-precision parts.

Ultrasonic Polishing

Ultrasonic polishing applies ultrasonic vibrations to titanium surfaces. It is a very quick and easy process that leaves behind a seamless finish.

The consistent production of ultrasonic vibration works efficiently regardless of the thrust force.

Tips for Effective Titanium Polishing

Some key tips for effective titanium polishing are as follows:

• Choose the right abrasives for polishing. The coarse grits are opted for the start and then gradually move towards the finer grits.
• Try to use wet sanding so that heat can be reduced and a smooth finish is achieved.
• Do not polish the entire surface in one go. Gradually polish stage by stage to attain optimal outcomes.
• Avoid using coolants as it leads to discoloration of titanium components.

Applications of Polished Titanium Parts

Polished components of titanium cater to various industries, and these are as follows:

Settore aerospaziale

Aerospace uses titanium components which are polished as they offer excellent resistance against corrosion. These components are high-strength and lightweight. Engine components of aircraft are manufactured using these parts.

Medical Sector

Il medical sector uses titanium polished parts in orthopedic and dental departments. These polished titanium components are used in knee, hip, and dental implants. They offer excellent resistance to chemicals and have high strength.

Settore automobilistico

The automobile industry uses titanium polished components in its vehicles as they offer a high strength-to-weight ratio. These components enhance the fuel efficiency of the vehicle, causing it to incur low operating costs.

Moreover, being corrosion resistant, these components are used in exhaust systems of cars as well.

Marine Sector

Titanium is also a commonly adopted material when it comes to marine applications. The polished titanium is marine grade due to its high resistance against corrosion and strength in seawater.

The titanium components can withstand the effects of the environment and hence work well as sea equipment.

Other Surface Finishes Compatible with Titanium Parts

The titanium components, after machining, can be subjected to some other types of surface finishes, too, and these are as follows:

Anodizzazione

It is an electrochemical process of finishing in which the titanium component is dipped in an electrolyte, and current is passed through it. The process transforms the surface of titanium into titanium oxide, which is durable and resistant to corrosion.

Spazzolatura

This process gives titanium components a bright and flawless surface. The marks of cutting tools and scratches can easily be removed. It enhances the surface using abrasive brushes.

Galvanotecnica

It is a process in which the titanium components get a layer of protection created on the surface. The metals used for adding this layer are tin, nickel, and gold. It improves the corrosion and wear resistance.

Rivestimento in polvere

Powder coating is a process of application of dry powder to titanium components. It enhances the aesthetic finish of titanium components.

Conclusione

Titanium polishing enhances the surface of the titanium components in a very commendable way.

If you want to have the titanium components polished for various applications, you can contact us at DEK. We offer different polishing methods and processes at affordable prices and excellent finishing.

Domande frequenti

Can you polish old titanium parts?

Yes, polishing an old titanium part would make it look as good as new.

What is the best buffing compound for titanium?

Green rogue is the best buffing compound for titanium.

How do I choose a buffing wheel for titanium polishing?

When choosing the buffing wheel, look at the ply– the higher the ply, the wider and thicker the buffing wheel will be.

What type of sandpaper works on titanium?

Sandpaper, which is made of silicon carbide of aluminum oxide, is the best for titanium.

What are the common titanium polishing tools and equipment?

The tools and equipment used in titanium polishing are polishing pads, abrasive components for polishing, buffing and cotton polishing wheels, brushes, and sisal.