Custom Extruded Aluminum Heatsink

What is the assembly process of aluminum radiator extrusions? How to ensure the matching accuracy and connection strength of each component?

The assembly of extruded aluminum heatsink usually includes the following key steps: component preparation, pretreatment, precision assembly, quality inspection and testing, and final packaging and delivery. Each step contains high technical requirements and delicate operation procedures.
1. Component preparation
Material selection and cutting: First, according to the design requirements of the radiator, we select high-quality aluminum alloy materials such as 6061-T6 or 6063-T5, which have excellent thermal conductivity and good processability. Using high-precision CNC cutting machines, ensure that the dimensional accuracy of each heat sink or heat sink is within ±0.1mm.
Surface treatment: In order to improve the corrosion resistance and aesthetics of the aluminum radiator, all components must undergo surface treatment processes such as anodizing, electrophoretic coating or powder spraying before assembly. Our company has an advanced surface treatment production line that can ensure uniform coating, strong adhesion, and compliance with environmental protection requirements.
2. Pretreatment
Cleaning and degreasing: Before assembly, all parts must be strictly cleaned and degreased to remove surface dirt and grease to ensure the quality of subsequent bonding or welding.
Precision machining: For parts that require precise matching, such as slots for heat sinks and grinding of fixing holes, we use CNC machining centers for high-precision machining to ensure that the matching clearance is controlled at the micron level.
3. Precision assembly
Choice of assembly method: According to the structural design and performance requirements of the extruded aluminum radiator, select a suitable assembly method, such as welding, riveting, gluing or mechanical fixing. We are particularly good at rivet-free connection technology and laser welding technology, which can achieve high-strength and high-precision connections without destroying the material structure.
Assembly process: During the assembly process, tooling fixtures are used to ensure the accurate positioning of each component, and precision measuring tools (such as three-coordinate measuring machines, image measuring machines, etc.) are used to monitor the assembly accuracy in real time to ensure that the assembly error is less than 0.2mm.
4. Quality inspection and testing
Appearance inspection: Perform a comprehensive appearance inspection on the assembled extruded aluminum heat sink to ensure that there are no defects such as scratches, cracks, and missing coating.
Performance test: Use thermal conductivity tester, pressure tester and other equipment to test the heat dissipation efficiency and pressure bearing capacity of the heatsink to ensure that the product meets the design requirements and customer standards. In addition, we will conduct 99.99% full inspection of finished products according to customer requirements to ensure that each radiator can meet the highest quality standards.
Reliability test: Conduct vibration test, salt spray test, high temperature and high humidity test, etc. to verify the stability and durability of the radiator in different environments.
5. Packaging and delivery
Protective packaging: Use anti-static and moisture-proof packaging materials to ensure that the extruded aluminum heatsink is not damaged during transportation.
Pre-delivery inspection: Perform quality inspection again before delivery to ensure that all products meet delivery standards.
Measures to ensure the matching accuracy and connection strength of each component
1. High-precision design and manufacturing
Our company has a team specializing in aluminum profile design, relying on self-developed technology to continuously optimize the design and manufacturing process. Through CAD/CAM/CAE software, accurate three-dimensional modeling and simulation analysis are carried out to ensure the accuracy and feasibility of the design stage. At the same time, advanced CNC machining equipment is used to ensure the dimensional accuracy and shape accuracy of each component.
2. Advanced testing technology
We are equipped with the industry's top testing equipment, such as film thickness and paint film testers, metallographic microscopes, Vickers hardness testers, etc., to test key indicators such as the physical and chemical properties of materials, coating quality, and hardness. Coordinate measuring machines and image measuring machines are used to accurately measure the size and shape of each component to ensure the accuracy requirements before assembly.
3. Professional connection technology
We use the most suitable connection technology for different application scenarios. For example, laser welding technology can achieve seamless connection and ensure heat conduction efficiency; rivet-free connection technology can provide high-strength connection without damaging the material. In addition, we have developed a series of special connectors and fixtures to ensure the stability and durability of the connection parts.
4. Comprehensive quality control system
We have established a complete quality control system, from raw material procurement, production and processing, assembly testing to finished product delivery, every link has strict quality control standards and processes. With ISO 9001 quality management system certification, we ensure that every step of the operation meets international standards and provides customers with reliable and high-quality products.