I have been working in a die-casting factory for many years. Recently, I received two special orders. One is an order for perfume caps. In the past, such perfume caps were all made of zinc alloy. Now, to meet the strict environmental protection policies of Europe and the United States, customers strongly demand that the die casting zinc alloy caps be changed into die-cast aluminum alloy caps and that the surface decoration adopt an oxidation process. The other order is for an LED outdoor lamp. Considering outdoor use, the customer requires that the surface decoration adopt an oxidation process to obtain a better oxidation protection layer and prevent natural oxidation. Looking at these two orders, I thought deeply, and pressure followed.

In fact, many factories have shown hesitation and reluctance in the entire die casting industry when facing similar orders for die-cast aluminum alloy oxidation treatment. So, what is the reason that makes factories reluctant to undertake die-cast aluminum alloy oxidation treatment? Is it a cost, technical problem, or other factors at play? Our factory faces This dilemma and a complex issue that the entire industry urgently needs to solve.

Cause Analysis

Next, we will analyze multiple aspects in-depth to determine why factories hesitate to undergo die-cast aluminum alloy oxidation treatment. Through such an analysis, we can better understand the problems and take adequate measures to avoid them.

1，Raw Material Cost

Although the fluctuation in raw material costs for die-cast aluminum alloy oxidation treatment and the procurement cost of high-quality aluminum alloy raw materials may bring certain economic pressure, this usually is not sufficient to be the main reason for Die Casting Manufacturer to refuse to undertake such business alone.

2，Market Changes

The instability of market demand significantly affects factories' enthusiasm for die-cast aluminum alloy oxidation treatment.  In the past, die-cast aluminum was less frequently subjected to oxidation treatment.  It was mainly used in some fields with low requirements for surface treatment or by adopting other relatively simple surface treatment methods.

3，Technical Difficulties

Difficulty in ensuring surface cleanliness: The surface of die-cast aluminum alloy usually has release agents, oil stains, sand holes, etc. Also, the aluminum alloy product will form an oxide layer after die-casting. Strong acids or solid alkalis and other chemical reagents must be used to clean it thoroughly before the oxidation process can occur. If it is not cleaned correctly, it will affect the growth and quality of the oxide film.

Technical problems during the oxidation treatment process: Various colorful aluminum oxidation products seen on the market are usually made of some pure aluminum materials, such as 6061. Because these materials are relatively single, their oxidation treatment processes are relatively mature and stable.

Then, the composition of die-cast aluminum alloy is relatively complex. Its silicon content will cause phenomena such as peeling, graying, and blackening on the oxidized surface, resulting in uneven color.

Solutions

Improve Surface Cleanliness

Before performing oxidation treatment on die-cast aluminum alloy products, cleanliness needs to be ensured. The main processes are as follows:

Polishing: Spend more time and use better polishing equipment to ensure the surface is flat and smooth.

Cleaning: Choose a cleaner with a better cleaning effect. It is best to completely clean impurities such as release agents, oil stains, and oxide layers. At the same time, try other cleaning methods such as ultrasonic cleaning, spray cleaning, and immersion cleaning.

Clean with purified water to remove residual cleaners and impurities, and perform drying treatment to prevent moisture from remaining on the surface of die-cast aluminum alloy parts, thereby reducing the impact on subsequent oxidation treatment.

Choose a darker oxidation color: Choosing a darker oxidation color can reduce some problems of darkening and graying of oxidation because darker colors can cover these problems.

Increase cost budget: If you must have a lighter and brighter oxidation color, you must be prepared to increase the cost budget. Even if all the previous steps are done perfectly, there will still be a relatively high defect rate. You can only re-clean and re-oxidize defective products, directly scrap them, and select good products with good oxidation.

Find an alternative oxidation process: If, after detailed evaluation and analysis, the defect rate caused by the oxidation of die casting aluminum alloy parts is high, it does not meet the project budget. Oxidation treatment is not necessary. Then, you can choose some other processes for substitution, such as electroplating and spraying.

Conclusion

Factories are reluctant to undertake orders for die-cast aluminum alloy oxidation treatment due to cost fluctuations, unstable market demand, and technical difficulties. Technical difficulties, such as ensuring surface cleanliness and numerous oxidation problems caused by complex compositions, are key obstacles. Problems can be alleviated by improving surface cleanliness, choosing darker oxidation colors, making high-cost budgets, or considering alternative processes, but more resources must be invested. In the future, the die-casting industry needs to strengthen technological research and development, reduce costs, and strengthen cooperation to promote the development of oxidation treatment technology and make factories no longer hesitate.