Design review
Wall thickness distribution, parting line and draft angles are read for castability. A correction here lightens the load on every step that follows.
Quality & R&D
OUR QUALITY APPROACH
Quality is not an inspection step, it is the process itself
Rather than sorting parts at the end, we aim to catch a deviation at the station where it appears. In practice that means quality starts at the die design, not at the measuring table. If we commit to a tolerance, we have a method that measures it and a record of it; we do not commit to what we cannot measure.
- Deviation is caught where it appears, not sorted out at the end
- Alloy composition is analysed on every casting batch
- Dedicated control plan and gauges for critical dimensions
- The measurement report is delivered with the part
- Scope
- Quality & R&D
- Manufacturer
- Kılıçaslan Aluminium Solutions
METROLOGY AND TESTING
What we measure and how
Each method answers a different question, so which one comes into play and when is written into the control plan for that part.
- Coordinate measurement (CMM)Dimensional verification and a measurement report. A dedicated control plan is prepared for critical dimensions.
- SpectrometryAlloy composition by optical emission. Iron content in particular is watched because of returned scrap.
- X-ray inspectionNon-destructive assessment of internal porosity and shrinkage in load bearing sections.
- Leak testingAir or liquid leak checking on housings that work under pressure.
WHERE QUALITY STARTS
Six steps to preventing deviation
The sequence below is not a checklist but the order in which decisions are taken. Each step closes the risk left by the previous one; a skipped step comes back as scrap at the very end.
Filling simulation
Regions at risk of trapped air, cold shuts and shrinkage are seen before any die steel is cut. Trial count and die revision cost drop here.
Trial shots
First parts are sectioned and measured; the acceptance criterion is put in writing before series production starts.
Process records
Injection speed, die temperature and intensification pressure are on record. When a batch drifts, the shot where it began can be traced back.
Measurement and testing
The methods written in the control plan are applied: dimensional measurement, alloy analysis and, where required, X-ray and leak testing.
Traceability
Casting batch, alloy analysis and measurement records can be traced back from the part. In industries with high documentation expectations, that chain is part of the delivery.
R&D
On the reverse engineering side, parts that exist only as physical samples are 3D scanned into a model and then redesigned for casting. This serves both for reproducing a spare of an old part and for moving a part made by another process into die casting.