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Manufacturing Instructions For Custom Made Toyota Supra Spoiler (Labtest)

The document provides manufacturing instructions for a custom-made Toyota Supra spoiler made of aluminum alloy 6061-T6. It involves (1) casting the alloy using patterns and molds, (2) heat treating it through solution heat treatment and artificial aging, (3) CNC machining it to specifications, and (4) assembly through welding, sealant application, and fastening.

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Thanes Waran
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33 views3 pages

Manufacturing Instructions For Custom Made Toyota Supra Spoiler (Labtest)

The document provides manufacturing instructions for a custom-made Toyota Supra spoiler made of aluminum alloy 6061-T6. It involves (1) casting the alloy using patterns and molds, (2) heat treating it through solution heat treatment and artificial aging, (3) CNC machining it to specifications, and (4) assembly through welding, sealant application, and fastening.

Uploaded by

Thanes Waran
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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MANUFACTURING INSTRUCTIONS FOR CUSTOM

MADE TOYOTA SUPRA SPOILER

1. Material Designation: Aluminium Alloy: 6061-T6


• This alloy is characterized by good weldability, high strength, and corrosion
resistance.
2. Casting Process:

a. Pattern Making and Mold Preparation:

Pattern Making:
• Create a detailed pattern of the spoiler using CAD software.
• The pattern should reflect the final shape and design.

Mold Making:
• Use the pattern to create a mold for casting.
• Choose a suitable molding material, such as sand or investment casting,
depending on the complexity of the design.

b. Foundry:

Melting Alloy:
• Melt the aluminium 6061-T6 alloy in a foundry furnace.
• Ensure the temperature is sufficient for proper casting.

Pouring:
• Pour the molten aluminium into the prepared mold.
• Allow it to cool and solidify.

Removal from Mold:


• Once solidified, remove the casting from the mold.
• Clean and inspect the casting for any defects.
3. Heat Treatment:

a. Solution Heat Treatment:

Heating:
• Preheat the cast or machined aluminium spoiler to a temperature between
477°C to 532°C.
• Hold the temperature for a sufficient duration to allow the alloying elements
to dissolve. The recommended time is typically 1 to 2 hours.

Quenching:
• Rapidly cool the spoiler by quenching it in a suitable quenching medium, such
as water or polymer.
• Achieve a fast and uniform cooling rate to prevent the formation of
undesirable phases.

b. Artificial Aging:
• Heat the spoiler to a lower temperature, typically around 177°C to 204°C.
• Hold the temperature for a specified time, usually between 4 to 12 hours.
• The aging process allows the precipitation of strengthening phases within the
aluminium matrix.

4. CNC Machining:
• Secure the cast spoiler in a CNC machine.
• Use proper fixturing to ensure stability during machining.
• Perform rough and finish machining as needed.

5. Assembly Processes:

a. Welding:

Surface Preparation:
• Clean and degrease surfaces to be welded.
• Remove any oxide layers.

Welding Method:
• Use Tungsten Inert Gas (TIG) welding for precise and clean welds.
• Adjust parameters for welding aluminium.
b. Sealant Application:

Surface Cleaning:
• Thoroughly clean surfaces with a suitable solvent.

Sealant Selection:
• Choose a sealant compatible with aluminium surfaces.

Sealant Application:
• Apply the sealant evenly to mating surfaces.

c. Fastening:

Fastener Selection:
• Choose corrosion-resistant fasteners suitable for aluminium.

Installation:
• Drill precise holes for fasteners.
• Torque fasteners to specifications.

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