Metallic housing forming method

1. Technical Field

The present disclosure relates to metallic housing forming methods, and more particularly, to a metallic housing forming method having a friction stir welding process.

2. Description of Related Art

Aluminum, zinc, and magnesium alloys are used in metallic housings due to a lower density and a high conductivity coefficient. A couple of metallic members are typically combined together to form a metallic housing by welding process. The metallic housing is then treated by anode-oxiding procedure to avoid corruption. However, a corrosion line may be produced on the metallic housing during the anode-oxiding process, and chromatic aberration is produced between the welding portion and other portions of the metallic housing. Thus, it is very difficult to obtain an attractive appearance on the metallic housing.

Therefore, there is room for improvement in the art.

The components in the drawings are not necessarily drawn to scale, the emphasis instead placed upon clearly illustrating the principles of the present disclosure.

FIGS. 1A and 1B show a flow chart of an embodiment of a metallic housing forming method.

FIGS. 1A and 1B show a flow chart of an embodiment of a metallic housing forming method. The detail steps of the forming method are as follows:

Step S 101 , two metallic members are provided to be welded by a friction stir welding process to form a metallic housing. In the embodiment, the metallic housing is computer housing made of 5052 aluminum.

Step S 102 , a clearing process is applied to an outer surface of the metallic housing.

Step S 103 , a surface blasting process is applied to the outer surface of the metallic housing.

Step S 104 , a degreasing process is applied to the metallic housing to remove contaminants. In the embodiment, the metallic housing is immersed in an alkali solution, such as NaOH, Na 2 CO 3 , Na 3 PO 4 liquid. Greases adhering on the metallic housing react with the alkali solution and generate many kinds of soluble salts, which may then be removed.

Step S 105 , the metallic housing is immersed in an alkali solution to remove contaminants from the metallic housing. In detail, the metallic housing is immersed in the alkali solution such as NaoH solution for a period of time. The outermost surface layer of the metallic housing reacts with the solubility alkali solution to improve a roughness and a brightness of the metallic housing. In the embodiment, a black layer consisted of NaAlO 2 is formed on the outer surface of the metallic housing during the immersing process by the reaction. The NaAlO 2 layer is a black soluble salt layer (black layer).

Step S 107 , an electro-polishing process is applied to the metallic housing to dissolve the extreme outer surface of the metallic housing, for obtaining a better appearance. In the embodiment, a direct current (DC) electrical charge is employed to polish the metallic housing and restrain a redox-reaction between the metallic housing and the alkali solution. Firstly, the metallic housing is immersed in the electrolyte, the metallic housing is employed as an anode electrode, and an insoluble metal is employed as a cathode electrode. In the embodiment, the cathode electrode is made of stainless steel. The electrolyte consists of sulphuric acid, orthophosphoric acid and aluminum ion. A volume ratio of the sulphuric acid and orthophosphoric acid is about 2.5˜4. Preferably, the volume ratio is about 3±0.3. The concentration of the aluminum ions is about 10˜20 grams per liter. Preferably, the concentration of the aluminum ions is about 15 grams per liter. The temperature of the electrolyte is about 70˜82 degrees Celsius. Preferably, the temperature is about 77±2 degrees Celsius. Secondly, the DC electrical charge is provided to the electrolyte and the metallic housing to take up an electro-polishing process. A value of the DC electrical charge in amperes is about 1.0˜1.5 times the surface area of the outer surface of the metallic housing in square decimeters. In the embodiment, the surface area of the metallic housing is 70 square decimeters, the value of the DC electrical charge varies from 70 to 105 amperes. Preferably, the value of the DC electrical charge is about 100±20 amperes. The duration of the electro-polishing is about 12˜38 seconds, and preferably the duration is about 20±2 seconds. In the process, the DC electrical charge is capable of restraining a redox-reaction between the metallic housing and the alkali solution. Moreover, impurities of the welding portion of the alkali solution are unable to generate a corrosion line by the redox-reaction. During the electro-polishing process, an outer surface of the metallic housing is dissolved to some extent and becomes smoother and more reflective. The glossiness coefficient of the metallic housing is about 33˜45.

Step S 108 , the metallic housing is taken out and dried. The metallic housing is taken out from the electrolyte and held exposed to the atmosphere for a period of time. In the embodiment, the period is about 12 seconds. The period of the metallic housing being exposed to the atmosphere can be changed according to the outer surface of the metallic housing.

Step S 109 , an anode-oxiding process is applied to the metallic housing. In the embodiment, the voltage of the anode-oxiding process is about 12.5 volts, and the temperature is about 12˜23 degrees Celsius. The time period of the anode-oxiding is about 21˜23 minutes.

Step S 110 , the metallic housing is sealed and dried. In sealing, the metallic housing is immersed in boiling water or nickel acetate solution for about 10 minutes to seal micro-structures on the surface of the metallic housing, for decreasing an adsorptive capacity of the surface of the metallic housing.

As the metallic housing is fabricated by a friction stir welding process, damage or trauma to the welded portion of the metallic housing is decreased. The surface of the metallic housing is dissolved to some extent and becomes smoother and glossier, thus a more attractive appearance is achieved. Any impurities of the welded portion are unable to generate a corrosion line by the redox-reaction, such that an appearance of the metallic housing is far less prejudiced.

The steps of S 102 , S 103 , S 104 may be omitted, when an independent surface blasting process is not needed.

The magnitude of the DC electrical charge employed in the electro-polishing process may be changed according to the nature of the outermost surface of the metallic housing.

The metallic housing may be made from aluminum alloys, or other light metal materials capable of undergoing an anode-oxiding process, such as magnesium/ferrous/ferric/magnetism alloy.

Finally, while various embodiments have been described and illustrated, the disclosure is not to be construed as being limited thereto. Various modifications can be made to the embodiments by those skilled in the art without departing from the true spirit and scope of the disclosure as defined by the appended claims.