Select A36 carbon steel as the casting raw material. Strict incoming material inspection is carried out to test chemical composition, tensile strength and yield strength. Raw materials with excessive impurities, slag inclusions and internal defects will be rejected. Fabricate casting molds engraved with product specification marks. Complete mold preheating and release agent coating treatment to guarantee sharp casting profile, clear marking and smooth surface for the swivel flange blank.
2.Casting & Forming
Melt qualified A36 carbon steel under precisely controlled temperature. Pour molten steel into the pre-treated mold cavity to form integrated cast blanks, including pipe socket, hinged swivel joint and rectangular base plate with mounting hole pre-position. Regulate pouring speed and cooling rate to avoid shrinkage cavities, pores and deformation. Ensure the blank has compact internal structure, uniform wall thickness and complete contour of hinge lugs and base plate.
3.Deburring, Shot Blasting & Machining
Remove casting gates, risers, flash and sharp burrs by grinding. Conduct shot blasting to clear surface sand residue and oxide scale. Perform precision machining on threaded bosses and tap internal threads for hex socket set screws. Drill and ream fixing holes on the base plate, finish hinge pin holes to match the pin assembly requirement. Verify inner diameter of pipe socket to meet tolerance for round pipe insertion.
4.Surface Pretreatment
Implement multi-stage pretreatment including degreasing, pickling and activation. Fully remove oil stains, rust and oxide layers on the casting surface. Rinse and dry the workpiece thoroughly to achieve a clean and active substrate surface, which can greatly improve the adhesion of subsequent composite zinc coating.
5.Composite Electro-galvanizing & Hot-dip Galvanizing
Adopt combined electro-galvanizing and hot-dip galvanizing processes to form composite anti-corrosion zinc layer with total thickness up to 80μm. Electro-galvanizing provides a thin, uniform base zinc layer covering complex hinge and threaded areas. Hot-dip galvanizing builds up thick protective coating, enhancing overall anti-rust and corrosion resistance, suitable for outdoor and humid working environments.
6.Final Inspection & Packaging
Carry out comprehensive quality inspection, including zinc coating thickness test, dimensional tolerance check, thread fit test, hinge rotation flexibility test and surface visual inspection. Label qualified swivel flange fittings with material grade, specification and batch number. Pack finished products with anti-scratch protective packaging to prevent surface damage during storage and transportation.