Core Production Process List for Golf Cart Aluminum Alloy Frame

I. Pre-Pretreatment Stage

1. Profile Cutting: Precisely cut each section of the profile according to the frame design drawings, ensuring a dimensional tolerance of ±0.5mm and a smooth, burr-free end surface.
2. Surface Degreasing: Remove oil stains and dust from the profile surface using an alkaline cleaning solution to avoid affecting the adhesion of subsequent welding/spraying.
3. Straightening Treatment: Straighten deformed profiles after cutting to ensure the straightness of components and prevent deviations in pipe bending/assembly.

II. Forming & Processing Stage

1. CNC Pipe Bending: Core curved components (such as frame side rails, front and rear crossbeams) are processed by CNC pipe bending machines to precisely control the bending radius and angle, achieving one-time forming without wrinkles, with a pipe bending tolerance of ±1°.
2. Punching/Milling Grooves: Perform CNC punching/milling grooves on parts requiring assembly and connection (such as suspension, steering, and battery mounting positions) to ensure accurate hole positions and smooth notches, adapting to fastener assembly.

III. Welding & Assembly Stage

1. Fixture Positioning: Place each formed component on a dedicated welding fixture for precise positioning and clamping, ensuring the overall dimensional accuracy of the frame and preventing welding deformation.
2. TIG Welding: Adopt TIG welding process for welding, focusing on the main load-bearing points and connection points of the frame. The welds are uniform and continuous, free of slag inclusions, pores, and incomplete penetration, and the weld leg height meets design requirements.
3. Post-Welding Shaping: Shape and straighten the slightly deformed frame after welding to restore overall dimensional accuracy and ensure the frame’s squareness.
4. Weld Seam Treatment: Grind and polish the surface of the weld seam to remove weld scars and burrs, making the transition between the weld seam and the base material smooth and avoiding stress concentration.

IV. Surface Treatment Stage

1. Pickling & Passivation: Remove oxide scales and weld slag from the surface after welding to form a passivation film, improving the frame’s corrosion resistance.
2. Electrostatic Powder Coating/Electrophoresis: Two mainstream processes — ① Electrostatic Powder Coating: Spray epoxy/polyester powder and cure at high temperature, resulting in high surface hardness and scratch resistance; ② Electrophoresis: Cathodic electrophoresis coating, with uniform paint film that can cover the inner cavity, offering superior corrosion resistance, preferred for high-end models.
3. Drying & Curing: Control the drying temperature (160-180℃) and time according to the coating process requirements to ensure complete curing of the paint film, strong adhesion, and no sagging or pinholes.

V. Final Assembly & Commissioning Stage

1. Accessory Pre-Installation: Assemble auxiliary accessories such as steering knuckles, suspension brackets, shock absorbers, brake line brackets, battery trays, and motor mounts on the frame. Use standard fasteners and tighten them to the specified torque.
2. Dimensional Inspection: Detect key parameters such as the overall outline size, track width, wheelbase, and spacing of mounting holes of the frame, all meeting the requirements of the design drawings.
3. Assembly Compatibility Test: Simulate assembly with the vehicle body, three-electric system, and running system to ensure accurate adaptation of each mounting position without interference or jamming.

VI. Finished Product Inspection & Packaging Stage

1. Comprehensive Inspection: Including dimensional accuracy inspection, non-destructive weld testing (for key load-bearing points), surface paint film inspection (adhesion, thickness), and torsional rigidity testing. Unqualified products are directly reworked.
2. Cleaning & Packaging: Clean the surface of the qualified frame, cover it with a protective film to prevent scratches during transportation. Batch frames are packaged in custom cartons/wooden frames with anti-collision and moisture-proof treatment.
3. Warehousing & Stocking: Store according to order classification, with clear labels for easy subsequent vehicle assembly or export delivery.

VII. Key Process Control Points

1. Full-Cycle Dimensional Tolerance Control: Control dimensional accuracy in all links to avoid cumulative deviations affecting vehicle assembly.
2. Welding Quality Control: Extract samples from each batch of frames for weld tensile testing to ensure welding strength meets national/enterprise standards.
3. Surface Treatment Quality Control: Paint film thickness inspection (60-80μm for powder coating, 20-30μm for electrophoresis), adhesion cross-cut test ≥ Grade 0, salt spray test ≥ 500 hours without rust.