1. Material and its control.
The AK12M2 alloy related to the aluminium-silicon-copper alloys is used in manufacture. It exhibits good yield and is used to make shaped castings by die casting. The high silicon content in the alloy (about 12%) results in low metal ductility. It would be possible to eliminate such a demerit by heat treatment, but it is not used for AK12M2. This material is used in the machine-building industry to manufacture a wide range of products and components for cars, tractors and other machinery. The alloy is examined for compliance with GOST 1583-93 by spectral analysis in the in-house laboratory.
2. Aluminium melting.
Aluminium is melted in MARCONI automatic furnaces (Italy). Five melting complexes of the shaft- and pump-type of different capacities are installed at the factory, they ensure the continuous supply of molten aluminium. The melting point of aluminium is 700 degrees Celsius. About 15 tons of aluminium are melted per day.
3. High-pressure die casting.
The factory has five automatic complexes that ensure aluminium melting for the manufacture of two types of sections of Series 80 and 100. Automatic melting complexes use two-cavity moulds. The moulds are used with a thermostatting system and maintained every 20,000 blows.
Machining of sections is carried out using grinding machines with the 60/80/100 grit abrasive band for different parts of the section. The bottom is welded using automated equipment. Welding joints at the bottom are machined with a milling machine. A thread is cut with an automated threading machine.
5. Pressure test of sections.
Pressure test of sections is carried out using special equipment. The section is immersed in water and checked with an air pressure of 30 Bar; if air bubbles appear in the water, the section is rejected. If there are no air bubbles, the section is transferred for the assembly.
6. Assembly and pressure test.
Sections are assembled with the use of nipples using special equipment and tightness is ensured by paronite gaskets. After assembly, the finished product is placed on the pressure test bench and tested for defects. The air pressure on the bench is 18-24 Bar. It is enough to detect a defect.
7. Degreasing and conversion coating.
After assembly, the finished product is prepared for painting. Firstly, it is degreased using a jet device under the pressure of 1.5 atm. After degreasing, a conversion coating is applied by the method of full immersion into a bath followed by polymerisation in a furnace.
8. Powder coating.
A primer is applied by anaphoresis with polymerisation. Then, gloss powder coating is applied. Further, the coated radiator is transferred for convection drying, where it is baked at a temperature of 170 degrees Celsius.
9. Pressure test and packaging.
After coating, radiators undergo the final pressure test. After the specialist makes sure of the product assembly and coating quality, the product is transferred for drying and packaging. At the stage of packaging, the product and a datasheet are boxed and sealed in a thick PVC film. The box complies with all requirements of international standards and GOST.