Incoming material
Identify the alloy and batch before use. Material documentation and any required composition check must refer to the accepted material, not an unrelated certificate.
QUALITY CONTROL / ALUMINUM COMPONENTS
Know what is checked.
See how it is measured.
A bearing bore, a gasket face and a coated exterior need different checks. Quality control starts with the feature and ends with a result tied to your drawing and production batch.
Send a drawing for review ↗
FEATURE → METHOD → RECORD
Inspection follows the part’s function.
The methods below explain how different requirements can be checked. The order’s inspection plan defines which methods, sampling levels and reports apply.
01 / DIMENSIONAL INSPECTION
The right tool for the feature.
CMM inspection evaluates coordinates and geometric relationships to the drawing’s datum system. Bore position, flange relationships and hole patterns need a defined alignment and measurement strategy.
Micrometers and bore gauges support close size checks; thread and pin gauges provide characteristic-specific acceptance checks. Calipers remain useful for suitable general dimensions.
For each critical characteristic, the report should show its drawing reference, tolerance, actual result and inspection status. A generic “dimensions checked” note is not a dimensional report.
| What is checked | Method / instrument | How the check is defined | Result to retain |
|---|---|---|---|
| Alloy chemistry | Spark optical emission spectroscopy (OES) | Check a prepared metal sample against the specified alloy composition. Link the result to the material or melt batch. | Element results, alloy specification and batch reference. |
| Bores, faces & hole patterns | CMM, bore gauges, micrometers and height gauges | Use drawing datums for feature relationships. Select a measuring tool with suitable resolution and uncertainty for the tolerance. | Ballooned drawing, nominal value, limits and actual readings. |
| Threads & simple sizes | Thread plug gauges, pin gauges and calipers | Check thread acceptance with the specified gauge class. Use calipers for suitable general dimensions, not as a substitute for every precision measurement. | Gauge identification, inspection frequency and acceptance result. |
| Internal discontinuities | 2D X-ray; CT or sectioning for a defined investigation | Identify the inspection zone, defect criteria and required coverage. X-ray images need interpretation; a visible indication is not automatically a reject. | Referenced images and evaluation against the agreed criteria. |
| Leakage | Pressure-decay, immersion or helium testing as specified | Define the test medium, pressure, stabilization and test duration, fixture seals and rejection threshold. Different methods are not interchangeable. | Test conditions, part identification and measured result or visual disposition. |
| Finish & surface condition | Visual reference, coating-thickness gauge and specified surface tests | Separate cosmetic zones from sealing faces and fits. Define lighting, reference samples, masking and the required coating checks. | Appearance result, thickness readings and any specified test records. |
| Mechanical properties | Hardness or tensile testing when required | Specify the method and specimen location or source. A separately cast coupon does not automatically represent every location in a finished part. | Test method, specimen condition and measured properties. |
02 / POROSITY & LEAKAGE
Internal quality and sealing are different questions.
Radiography examines internal indications. A leak test evaluates whether the part or assembly passes the specified leakage criterion under defined conditions. One does not replace the other.
On a machined enclosure, define the critical zones around the sealing face, threaded ports and thin sections. Inspection requirements may change after machining exposes material below the casting surface.
- For X-ray: specify zones, views, acceptance criteria and traceable image references.
- For a leak test: specify the part condition, sealed openings, medium, pressure and acceptance threshold.
- For an IP rating: validate the complete enclosure assembly, including gasket, fasteners and cable entries.
FROM MATERIAL TO SHIPMENT
Five checkpoints. A traceable batch.
Tool trial & first article
Check the trial casting after trimming and required machining. Number the drawing characteristics, report measured values and record open deviations before sample approval.
Casting & machining
Track the relevant process settings and changes. Check critical sizes at setup and at the specified intervals; tool wear, fixture seating and casting variation need separate attention.
Finishing & final inspection
Recheck features affected by coating or handling. Inspect masked areas, threads, sealing faces, cosmetic zones and any order-specific functional requirements.
Release & traceability
Match the accepted parts, drawing revision, lot reference and inspection records. Protect finished interfaces during packing and identify any approved deviation with the affected batch.
WHEN A RESULT IS OUTSIDE LIMITS
Contain the parts.
Resolve the cause.
A failed check needs an identified lot and a disposition. Sorting, rework or use under concession are different decisions; they must not be hidden behind a passing summary.
- Identify and separate the suspect parts, including the potentially affected production interval.
- Record the characteristic, actual result and drawing requirement; notify the project contact.
- Determine the cause and proposed disposition. Obtain customer authorization for a deviation where required.
- Reinspect reworked parts and retain the disposition and release records with the batch.
WHAT YOUR TEAM CAN REVIEW
A useful inspection package.
Specify the required package in the RFQ so its scope and cost are included in the quotation.
- Numbered drawing and dimensional results for the specified characteristics.
- Material batch reference and required composition or material documentation.
- Specified finish, leakage or internal-defect inspection records.
- Part number, drawing revision, sample or lot identification and disposition.
REPORT STRUCTURE / ILLUSTRATIVE
Drawing feature → measured result
- Identification
- Part number · revision · batch · sample
- Characteristic
- Balloon number · datum · tolerance
- Measurement
- Method · instrument reference · actual value
- Disposition
- Within limits / deviation reference
No fabricated measurements are shown here. Open the separately labeled simulated report ↗
Common inspection questions
Does every casting need 100% X-ray or helium testing?
No. Inspection coverage depends on the application, risk and order requirements. Specify the critical zones, method, sampling or full inspection requirement and acceptance criteria before pricing.
Can I receive a full dimensional report with the first samples?
Include the required characteristics, sample quantity and report format in your RFQ. A first-article dimensional report and a complete customer approval package are different scopes.
Can a material certificate replace a mechanical test?
No. Composition, hardness and tensile properties describe different attributes. The relevant specification must identify what is required and how the specimen represents the supplied part.
What should I send with a sealing-critical part?
Send the assembly drawing, sealing interfaces, machined condition, test medium, pressure, duration and permitted leakage. Identify whether the requirement applies to the bare casting, finished component or assembled enclosure.
Method references: ZEISS casting inspection · SPECTRO OES principle. References describe methods, not equipment ownership or certification.
QUOTE THE PART AND THE INSPECTION
Send the features that matter.
Attach the drawing and identify critical fits, sealing requirements and the records your receiving team needs.