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Quality Assurance · IATF 16949:2016

Quality Assurance for Aluminium Die Castings

Quality in die casting is built in at every stage — from the ingot we accept to the label on the box. This page explains how we inspect, record and improve.

Quality Policy

Our quality policy

We are committed to supplying aluminium die castings that meet customer requirements every time, by maintaining a documented quality management system, training our people, working with approved suppliers, and measuring our performance to improve continuously.

Read the 5-point quality policy

Certification

IATF 16949:2016

CERTIFICATE NUMBER : 0612600

Inspection Stages

Inspection from ingot to dispatch

  1. Stage 01

    Incoming & raw material inspection

    Aluminium ingots are accepted only from approved suppliers with mill certificates. Each lot is checked for identification and chemistry before it is released to the melting area.

    • ✓ Supplier certificate review
    • ✓ Ingot lot identification
    • ✓ Spectrometer chemistry check
  2. Stage 02

    Melt control

    Holding temperature is controlled at 685°C ± 5°C and the melt is degassed before transfer to reduce hydrogen porosity.

    • ✓ Melt temperature log
    • ✓ Degassing per batch
    • ✓ Chemistry verification per heat
  3. Stage 03

    Process inspection

    Setters approve the first shots of every run; operators check castings at a defined frequency against a control plan.

    • ✓ First-off approval
    • ✓ Patrol inspection
    • ✓ Process parameter recording
  4. Stage 04

    Dimensional inspection

    Critical dimensions are measured with gauges in-process and on the CMM for first-article and periodic audits.

    • ✓ Go/no-go and variable gauges
    • ✓ CMM layout inspection
    • ✓ Height-gauge checks on the granite table
  5. Stage 05

    Visual & surface inspection

    Castings are checked for cold shuts, flow lines, cracks, flash and surface damage against agreed boundary samples.

    • ✓ Defect catalogue
    • ✓ Boundary samples
    • ✓ Cosmetic criteria per customer
  6. Stage 06

    Final inspection & dispatch

    Before packing, each batch passes final inspection and is labelled for traceability, then packed to the agreed specification.

    • ✓ Final inspection report
    • ✓ Batch labelling
    • ✓ Packing to specification
Quality System

Traceability, control and improvement

Traceability
Each batch can be traced from dispatch label back to the production date, die, machine and melt heat. [INSERT TRACEABILITY METHOD — e.g. date coding / batch cards / ERP].
Rejection control
Non-conforming parts are segregated, recorded and analysed. Root causes are addressed with corrective actions and verified for effectiveness.
Calibration
Measuring instruments and gauges are calibrated on a schedule with records maintained. [INSERT CALIBRATION AGENCY / ACCREDITATION].
Quality documentation
We provide [INSERT DOCUMENTS — e.g. PPAP elements, inspection reports, material certificates] as agreed with each customer.
Continuous improvement
Quality KPIs such as rejection rate and die life are reviewed regularly to drive improvement projects. [INSERT CURRENT PPM / KPI — only if verified].
Supplier control
Ingot and consumable suppliers are approved and monitored for consistent chemistry and delivery.
Metrology

Inspection equipment

Quality inspection equipment at Sunmax Casting
EquipmentPurposeDetails
Coordinate measuring machine (CMM)First-article and periodic dimensional inspection[INSERT MAKE / MODEL / RANGE]
Optical emission spectrometerMelt and ingot chemistry verification[INSERT MAKE / MODEL]
X-ray / radiographyInternal porosity inspection of critical sections[INSERT — confirm in-house or outsourced]
Granite surface tableDatum surface for height gauges and dial indicatorsGrade 0
Leak testingPressure-tightness of housings and manifolds[INSERT METHOD / RANGE]
Hardness testerBrinell hardness of cast parts[INSERT MAKE / MODEL]

FAQ

Quality questions

Is Sunmax Casting certified?

Our quality management system is certified to IATF 16949:2016. Certificate copies are available on request.

How do you control porosity in aluminium die castings?

Through melt degassing, controlled shot profiles and intensification pressure, die thermal management, and inspection of critical sections — with acceptance levels agreed per part.

Can you share inspection reports with each shipment?

Yes. The documents supplied with each shipment are agreed during part approval.

Quality Documentation

Need inspection data with your RFQ?

Tell us your critical characteristics, acceptance levels and documentation needs when you request a quote.