The production process of the faucet
February 09 , 2023
1. The production process of the faucet
Sand core forming→sand core inspection→casting copper alloy smelting→chemical composition analysis and inspection→gravity casting→ceramic sand self-inspection→shot blasting and finishing→appearance inspection→pressure test→machining→appearance inspection→pressure test→lead release treatment→ Polishing→appearance inspection→foreign electroplating→appearance inspection (acetic acid salt spray test)→assembly→installation process self-inspection→process inspection→water test, pressure test→packaging→finished product inspection→storage→delivery inspection.
Second, the casting process of the faucet
1. What is casting
It usually refers to the method of making products with molten alloy materials. The liquid alloy is injected into the pre-prepared casting mold, cooled and solidified, and the blank or part with the required shape and weight is obtained.
2. Core making machine
Foundry equipment for making cores. According to the different methods of solid sand during core making, core making machines can be divided into vibrating core making machines, core extruding machines and core shooting machines.
3. Shot blasting machine
Casting equipment that uses high-speed projectiles thrown by a shot blaster to clean or strengthen the surface of castings. The shot blasting machine can shake out sand, remove core and clean the casting at the same time.
4. Molding machine
Foundry equipment for making sand molds. Its main functions are: filling sand, filling loose molding sand into the sand box, and compacting the molding sand.
5. Metal mold casting
Also known as hard mold manufacturing, it is a casting method in which liquid metal is poured into a metal mold to obtain a casting. The mold is made of metal and can be used repeatedly.
6. Sand casting
It is a traditional casting process that uses sand as the main molding material to make molds.
7. Gravity casting
It refers to the process of injecting molten metal (copper alloy) into the mold under the gravity of the earth, also known as metal casting. It is a modern process of making hollow casting molds for casting with heat-resistant alloy steel.
8. Cast copper alloy
The raw material used for faucet products is cast copper alloy, which has good casting performance, mechanical properties and corrosion resistance, and the casting has fine structure and compact structure. The alloy grade is ZCuZn40P62 (ZHPb59-1) based on GB/T 1176-1987 casting copper alloy technical conditions, and the copper content is (58.0~63.0)%, which is the most ideal faucet casting material.
9. Brass chemical analysis method
The main chemical composition analysis method of cast copper alloy adopted by the company is titration analysis method. According to the concentration and volume of the standard solution consumed by titration and the quantitative relationship between the chemical reaction between the measured substance and the standard solution, the content of the measured substance is calculated. This method is called titration analysis.
10. Brief description of the faucet casting process
First, on the automatic hot core box core shooter, sand cores are produced for backup, and the copper alloy is smelted (resistance furnace for smelting equipment). After the copper alloy reaches a certain melting state, chemical analysis is carried out to sample the copper alloy test block and send it to the laboratory for chemical titration. Analysis or spectral analysis, after confirming that the chemical composition of the copper alloy meets the requirements, pouring (the pouring equipment is a metal type gravity casting machine), after cooling and solidification, open the mold and unload the material to clean the pouring riser, and wait for the copper water in the resistance furnace to be poured , the cooled cast blanks are self-inspected and sent to the shakeout machine to clean the pottery sand. The next heat treatment (stress relief annealing) of the casting blank is aimed at eliminating the internal stress generated by casting. Put the blank into the shot blasting machine to achieve a more ideal casting blank, and ensure that the inner cavity is free from molding sand, metal shavings or other impurities. Then the casting blank is fully sealed, and the air is tested in water to test the sealing of the shell and the sealing of the partition. Finally, after quality inspection, analysis, inspection, classification and storage.
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