Select A36 carbon steel as raw material. Perform strict incoming inspection on chemical composition, tensile strength and yield strength, reject materials with impurities and internal defects. Prepare casting moulds engraved with product specification marks, carry out mould preheating and surface coating treatment to ensure clear casting outline and intact marking on the elbow blank.
2.Investment Casting & Forming
Melt qualified A36 carbon steel under precise temperature control. Pour molten steel into the pre-treated mould cavity to form integrated 90° elbow blanks with socket holes and pre-cast threaded boss positions. Control pouring speed and cooling rate to avoid shrinkage, porosity and deformation, guarantee uniform wall thickness and complete contour of the elbow body.
3.Deburring, Shot Blasting & Machining
Remove casting sprues, flash and burrs by grinding and shot blasting to clear residual sand and oxide scale on inner and outer surfaces. Carry out precision machining on the threaded bosses, tap internal threads for hex socket set screws. Ensure the socket inner diameter meets the tolerance requirement for matching round pipes.
4.Surface Pretreatment
Conduct multi-step pretreatment including degreasing, pickling and surface activation. Thoroughly remove oil stains, rust and oxide layers on the casting surface. Clean and dry the workpiece to get an active, clean substrate, which improves the adhesion of subsequent composite zinc coating.
5.Composite Electro-galvanizing & Hot-dip Galvanizing
Adopt combined electro-galvanizing and hot-dip galvanizing process to form composite anti-corrosion zinc layer with total thickness up to 80μm. Electro-galvanizing provides a uniform base zinc layer, then hot-dip galvanizing builds up thick protective coating. This treatment greatly enhances rust resistance and corrosion resistance, suitable for outdoor and humid working conditions.
6.Final Inspection & Packaging
Conduct full quality inspection including coating thickness test, dimensional check, thread fit test and appearance inspection. Mark qualified products with grade and batch information. Pack finished galvanized elbows with protective packaging to prevent scratches and collision damage during storage and transportation.