Die casting knowledge in the automotive industry

die-casting-applications-in-the-automotive-industry

Die casting knowledge in the automotive industry

Technology continues to evolve every day, and the automotive world is not far behind. In today’s marketplace, manufacturers and project managers continue to look for faster, more reliable and cost-effective ways to produce automotive parts. Hence, the advancement of automotive die casting technology.

Die casting is important to the automotive industry for a number of reasons. The technology is an effective alternative to metal fabrication, reducing the weight and improving the mileage of automotive parts without sacrificing quality. It helps create parts that are lighter, stronger and have thinner walls. This is a great contribution to the automotive industry.

Here, we will discuss the various roles of die casting in automobiles and cover the many applications of automotive part casting.

Contents

1. Why die casting in the automotive industry is on the rise?

2. Common Materials Used in Die Casting for Automotive Industry

3. Die Casting Process for Making Automotive Parts

4. Different Automotive Die Casting Parts

5. CustomRapidParts, Your Automotive Die Casting Services Partner

6. Automotive Die Casting Market Trends

7. Conclusion

Why Is Die Casting Rising in the Automotive Industry?

die-casting-applications-in-the-automotive-industry
die-casting-applications-in-the-automotive-industry

Over the past few years, automakers have focused on making lightweight vehicles that do not compromise durability. As a result, die casting is one of the most valuable technologies for manufacturing automotive parts. The number of die cast parts used for automobiles is increasing every day.

But why is there a dramatic increase in die casting demand from automakers? Here are some of the reasons.

Manufacturing of lightweight parts

The automotive industry now has more stringent fuel economy standards. The pressure to make more efficient vehicles is increasing. As a result, automakers are using aluminum die casting to achieve this goal.

Aluminum is a lightweight metal with an excellent strength-to-weight ratio. As such, it is the primary metal used to cast engine parts and wheels. As a result, manufacturers are now building lighter, safer vehicles by ensuring the quality of both exterior and interior components.

Increased automation and flexibility

The popularity of automotive die casting is increasing due to the growing use of advanced technology. Automation of the production process has made die casting more efficient and productive, ensuring that more automotive die cast parts are manufactured.

In addition, this method is very effective for developing complex automotive parts with unique designs. Die casting technology helps to manufacture parts with complex shapes and sizes and to easily install them in vehicles.

Improving the sustainability of components

Die casting of automotive parts also ensures the manufacture of environmentally friendly and sustainable automotive parts. Thus, we can ensure that the casting of automotive parts does not cause damage to the environment. In addition, the ability to recycle the materials used for these components makes them more valuable. For example, recycled aluminum can be recycled indefinitely.

Common Materials Used in Die Casting for Automotive Industry

Many metals can be suitable die casting materials, especially non-ferrous metals. However, the most common materials for die casting in the automotive industry are zinc, aluminum, and magnesium. These metals have their unique advantages and ideal applications. Let’s take a look at them.

Zinc Die Casting

zinc-die-cast-components
zinc-die-cast-components

Zinc die castings make up nearly 28% of automotive die castings. Although commonly used in industry due to its high impact strength and ductility, it is now popular in the automotive industry. Because it can be cast in a hot chamber die casting machine, the process is almost 100% accurate. As a result, it is possible to produce parts with smooth surfaces and without further processing.

This die-cast metal is particularly prominent in products such as door lock housings, winder gears, and seat belt pulleys. In addition, it is ideal for manufacturing automotive parts with quality aesthetic requirements, embossing or tight tolerances.

Advantages of Zinc Die Casting

Some of the advantages of zinc die casting include the following:

Increased Flexibility. Zinc beats other casting materials when it comes to fluidity. While aluminum is more lightweight than zing, it can help create intricate parts with complex shapes and thinner walls.

High Resistance to Corrosion. Zinc reacts very minimally upon exposure to the atmosphere. Therefore, parts made from this metal are usually durable. These die-cast parts often stay for extended periods without needing constant maintenance.

Excellent Thermal and Electrical Conductivity. We are in the era of advanced vehicles and smarter automobiles. Therefore, it is important to make their components with metals that can withstand those needs. Zinc conducts heat and electricity effectively, making it the ideal choice in this case.

Sustainability and Eco-friendliness. Zinc is environmentally friendly and is easily recycled into new products. Therefore, it is a great choice for automotive die casting to prevent excessive waste and the release of harmful substances into the environment.

Dimensional Stability. Zinc also beats other die-cast metals in terms of dimensional stability. Auto parts casting with zinc gives products with superior finish and aesthetic appeal.

Aluminum Die Casting

aluminum-die-casting-process
aluminum-die-casting-process

Aluminum is another popular metal used in the manufacture of automotive parts. Its light weight and good dimensional stability make it a popular choice for thin-walled machine parts. Typically, low-density aluminum is more widely used in the automotive industry. Automotive castings made of this metal have higher strength even at high temperatures.

The aluminum die casting process can produce thousands of castings at a time using steel molds. It is ideal for manufacturing engine mounts, transmission cases, valve bodies, hydraulic cylinders, and other parts.

Advantages of Aluminum Die Casting

The many benefits of aluminum die casting for automotive parts include:

Manufacturing Lightweight Components. 
As mentioned earlier, fuel economy standards are increasing for automotive manufacturers to make vehicles cleaner and more efficient. Therefore, engineers now improve the fuel economy of automobiles by reducing their overall weight. As a result, they opt for aluminum die casting to manufacture very lightweight parts. These parts are robust, efficient, and long-lasting.

Increased Flexibility. 
The latest vehicles now have components with more complex designs. Unlike many other metals, aluminum is more flexible, making it possible to develop complex aluminum die-casting auto parts with unique designs.

Safety and Reliability. 
Safety is another important factor that manufacturers consider in automotive parts production. Aluminum die casting makes it possible to create heat and friction-resistant parts to protect drivers and passengers from accidents.

Environmentally Friendly.
Like zinc, aluminum is also highly recyclable. In fact, it is possible to recycle some aluminum alloys indefinitely, making them more environmentally friendly. Moreover, aluminum parts production causes less environmental pollution, making it highly beneficial.

Magnesium Die Casting

magnesium-die-casting-parts
magnesium-die-casting-parts

Magnesium is another flexible and lightweight metal used in die casting. It contains other lighter metals and offers a wide range of possibilities for making complex and thin-walled parts. It also has an incredible strength-to-weight ratio and excellent heat and temperature resistance.

Advantages of Magnesium Die Casting

Some of the benefits of using magnesium die castings for automotive parts include

Manufacturing Lightweight Automobiles. 
Magnesium is a lightweight metal that also incorporates other lighter metals like aluminum. In addition, it offers an excellent strength-to-weight ratio. Therefore, it can help create well-performing lightweight auto parts.

Increased Corrosion Resistance. 
Newer magnesium alloys with higher purity ensure that manufacturers can achieve better corrosion resistance than aluminum or steel alloys.

Environmental Friendliness. 
Magnesium is a naturally occurring metal derived from minerals, seawater, and brines. Its widespread availability makes it easy to be harvested without affecting the environment. It can also be 100% recycled without leaving traces in the environment.

Die Casting Process for Making Automotive Parts

There are two basic die casting processes for manufacturing automotive components – hot chamber and cold chamber die casting machines. The process you choose will depend on your material choice, size, geometry, and complexity.

Hot Chamber Die Casting

hot-chamber-die-casting-process
hot-chamber-die-casting-process

The hot chamber die casting process is sometimes referred to as hot die casting. The gooseneck tube machine used in this process has a built-in furnace that heats the metal until it melts. A hydraulically powered piston uses nozzles and gooseneck tubes to force molten metal from the furnace into the mold cavity. The molten metal is then held under pressure in the mold cavity until it solidifies.

This type of die casting has an internal melting point. Therefore, it is best suited for metals with low melting points. Aluminum has a melting point of 1,220 degrees Fahrenheit and is therefore not suitable for this process. On the other hand, zinc and magnesium, which have relatively low melting points, are ideal for this process.

Hot chamber die casting offers fast production rates of more than 18,000 injections per hour for small automotive die cast parts. It melts the metal in the casting machine, producing minimal material waste. Because it is a low-melting-point process, it results in longer mold life and helps save on overall die casting costs. However, it is only cost effective for high volume production. Metal flow is also low, thus limiting product complexity.

Cold Chamber Die Casting

cold-chamber-die-casting-process
cold-chamber-die-casting-process

The process involves pouring molten metal into the injection sleeve of the injection barrel. After pouring, a hydraulic plunger forces the molten metal into the mold cavity without heating the sleeve. The pressures used in this process range from 30 Mpa to 150 Mpa. Since no heat is involved, the process is called cold chamber die casting. This process is ideal for high melting point aluminum alloys.

Cold chamber die casting provides superior dimensional accuracy for parts. It also produces higher strength automotive parts and more dense metal castings due to the increased pressure. The process is easy to perform and requires low maintenance costs. However, due to the transfer process, cycle times are slower than hot chamber processes. High levels of contaminants may also be present, which may affect the quality of the final automotive part.

Different Automotive Die Casting Parts

automotive-parts-from-die-casting
automotive-parts-from-die-casting

Automotive die casting helps to produce parts with complex shapes, high durability and improved aesthetics. Automotive die casting is used in a wide range of applications, including

  • Engine parts, such as cylinder heads and gas engine parts
  • Mounting brackets for motors and stepper motors
  • Electronic covers for gearboxes, motors, sun bars, etc.
  • Shields for telematics and electronic devices
  • Sensors and airbag housings as active safety mechanisms
  • Oil intake components
  • Air conditioning systems
  • Reel spools for seat belts
  • Intricate locking barrels
  • Transmission and chassis components
  • Connectors for self-driving cars
  • Sensor and LIDAR sheaths
  • Durable power steering and braking systems

CustomRapidParts, Your Automotive Die Casting Services Partner

Rapid-direct-die-casting-services
Rapid-direct-die-casting-services

At CustomRapidParts, we work with you to design and develop metal castings that exactly meet the requirements of your application. We are a leading automotive parts manufacturer with an excellent track record of producing high quality and lightweight automotive parts. Our expert technicians are skilled and experienced in die casting technology, so you can be assured that we will provide you with the best die casting service possible.

Our knowledge of various materials also helps us to select the most suitable material for your automotive parts. This will ensure that you get the best results for your project. You will get these products at competitive prices and faster delivery times. Upload your design files to our online manufacturing platform and get a quick quote.

Try CustomRapidParts Now!

All information and uploads are secure and confidential.

Get Quote

Automotive Die Casting Market Trends

various-automotive-die-casting-parts
various-automotive-die-casting-parts

The automotive die casting market is reportedly expected to exceed $20.31 billion by 2028. It earned $11.1 billion in 2022 and will grow at an annual rate of 7.8% from 2023 to 2029.

The increase in automotive parts die castings is constrained by the increase in income of middle-income groups, leading to growth in passenger car sales.

In addition, die castings help reduce the weight of vehicles, thereby minimizing fuel emissions and improving fuel efficiency. The production of eco-friendly parts will lead to the growth of these market trends.

Conclusion

Die casting has revolutionized the automotive world, helping to create high-quality, lightweight components. In turn, manufacturers can now meet industry requirements without sacrificing engine quality and efficiency.
In this article, we mention the basic die casting metals for the automotive industry and their unique advantages. This will help you make the right choice for your project. However, if you still have more questions about automotive die casting, contact CustomRapidParts today and let’s get started.

Scroll to Top