Select A36 carbon steel as casting raw material. Strict incoming inspection is implemented to test chemical composition, tensile strength and yield strength. Raw materials containing excessive impurities, slag inclusions and internal defects will be rejected. Produce casting molds engraved with product specification marks. Complete mold preheating and release agent coating treatment to ensure clear casting outline, legible marking and smooth surface for F-wall flange blanks.
2.Casting & Forming
Melt qualified A36 carbon steel under precisely controlled temperature parameters. Pour molten steel into the pre-treated mold cavity to form integrated cast blanks, including tubular socket and triangular base flange with pre-positioned mounting holes. Control pouring speed and cooling rate to prevent shrinkage cavities, pores and deformation. Ensure the blank has dense internal structure, uniform wall thickness and complete contours of the base lugs and pipe socket.
3.Deburring, Shot Blasting & Machining
Grind off casting gates, risers, flash and sharp burrs. Carry out shot blasting to remove residual sand and oxide scale on the workpiece surface. Perform precision machining on threaded bosses and tap internal threads for hex socket set screws. Drill and ream mounting holes on the triangular base plate. Check the inner diameter of pipe socket to guarantee the tolerance for round pipe insertion.
4.Surface Pretreatment
Adopt multi-stage pretreatment procedures including degreasing, pickling and surface activation. Fully remove oil stains, rust and oxide layers on the casting surface. Rinse and dry the workpiece thoroughly to obtain a clean and active substrate surface, which significantly improves the bonding strength of the subsequent composite zinc coating.
5.Composite Electro-galvanizing & Hot-dip Galvanizing
Apply combined electro-galvanizing and hot-dip galvanizing processes to form composite anti-corrosion zinc layer with total thickness up to 80μm. Electro-galvanizing creates a thin and uniform base zinc layer covering complex threaded and corner areas. Hot-dip galvanizing builds a thick protective coating to boost overall rust and corrosion resistance, suitable for outdoor and humid working conditions.
6.Final Inspection & Packaging
Conduct comprehensive quality inspection, including zinc coating thickness test, dimensional tolerance check, thread fit test and surface visual inspection. Label qualified F-wall flange fittings with material grade, specification and batch number. Pack finished products with anti-scratch protective packaging to avoid surface damage during storage and transportation.