Golf Cart Aluminum Alloy Frame Core Production Process List

Core Substrate: 6061-T6 aluminum alloy profile (mainstream) / 6063 aluminum alloy profile (economical), both extruded profiles, suitable for lightweight, corrosion-resistant, and high-rigidity frame requirements.

I. Pre-processing Stage

1. Profile Cutting: Precisely cut each section of profile according to the frame design drawings, ensuring a dimensional tolerance of ±0.5mm and a smooth, burr-free end face.

2. Surface Degreasing: Use alkaline cleaning solution to remove oil and dust from the profile surface to avoid affecting subsequent welding/painting adhesion.

3. Straightening: Straighten deformed profiles after cutting to ensure component straightness and prevent bending/assembly deviations.

II. Forming and Processing Stage

1. CNC Bending: Core curved components (such as frame side beams and front and rear crossbeams) are processed using a CNC bending machine, precisely controlling the bending radius and angle, forming in one go without wrinkles, with a bending tolerance of ±1°.

2. Punching/Milling: CNC punching/milling is performed on parts requiring assembly and connection (such as suspension, steering, and battery mounting positions) to ensure precise hole positions and smooth grooves, facilitating fastener assembly.

III. Welding Assembly

1. Tooling Positioning: Each formed component is placed on a dedicated welding fixture for precise positioning and clamping, ensuring the overall dimensional accuracy of the frame and preventing welding deformation.

2. TIG Welding: TIG welding is performed, focusing on key load-bearing points and connection points of the frame. Welds are uniform and continuous, free of slag inclusions, porosity, and incomplete welds, with weld leg height meeting design requirements.

3. Post-Weld Shaping: Slightly deformed frames after welding are shaped and corrected to restore overall dimensional accuracy and ensure frame squareness.

4. Weld Treatment: The weld surface is ground and polished to remove weld scars and burrs, ensuring a smooth transition between the weld and the substrate and avoiding stress concentration.

IV. Surface Treatment

1. 1. Pickling and Passivation: Removes oxide scale and weld slag from the welded surface, forming a passivation film to improve the frame’s corrosion resistance.

2. Electrostatic Powder Coating/Electrophoresis: Two mainstream processes—① Electrostatic Powder Coating: Spraying epoxy/polyester powder, high-temperature curing, high surface hardness, and scratch resistance; ② Electrophoresis: Cathodic electrophoretic coating, uniform paint film, covering even internal cavities, superior corrosion resistance, preferred for high-end models.

3. Drying and Curing: Controlling the drying temperature (160-180℃) and time according to the coating process requirements to ensure complete curing of the paint film, strong adhesion, and no runs or pinholes.