Automotive Parts Group Summary
1. Engine Accessories: Lightweight and precision-critical parts
Throttle body, fuel pump, fuel nozzle, tensioner, cylinder block, bearing bush, water pump, fuel injection, gasket, camshaft, valve plate, crankshaft, connecting rod assembly, piston, carburetor, fuel tank, water tank, fan, radiator, Pistons
2. Powertrain Accessories
- Precision gears and shafts: Gears, intermediate shaft, drive shaft assembly, drive shaft flange, synchronizer ring.
- Brake System Accessories: Brake disc, brake drum, brake master cylinder, brake cylinder.
- Steering System Accessories: Steering gear, steering knuckle, power pump.
- Suspension and Axle Accessories: Rear axle, half axle, balance weight.
- Electrical and Instrumentation Accessories: Precision and heat-dissipation-critical parts ( Ignition module, ignition coil, alternator housing )
- Automotive Lighting and Exterior Parts: Headlight housing, decoder housing, decorative automotive exterior parts.
- Body and Safety Components: Wiper housing, airbag casing, instrument panel housing.
- Maintenance Equipment and Others: Precision equipment casings and tool housings.
- Complex structural components:Transfer case, clutch disc, flange, planetary gear, wheel carrier.
 Frontal cross brace |  RHT folding levers |
Automotive Parts Advantages:
High-pressure aluminum die casting has revolutionized the production of automotive parts, offering numerous advantages such as lightweighting, high strength, and the ability to create complex shapes.
 Rear connector sill frame member |
1. Weight Reduction (Lightweighting):
One of the core challenges in the automotive industry is reducing vehicle weight to improve fuel efficiency and lower emissions. Aluminum is a lightweight material, approximately one-third the weight of steel, while still maintaining excellent strength. Producing aluminum parts through high-pressure die casting significantly reduces the overall vehicle weight, leading to improved fuel economy, acceleration performance, and handling. Lightweighting is even more critical for electric vehicles (EVs) as it directly impacts battery efficiency and driving range.
2. High Strength and Durability:
High-pressure die casting involves injecting molten aluminum into a mold under high pressure. This process results in a dense metal structure with minimized porosity, leading to parts with high strength and durability. Aluminum also exhibits excellent corrosion resistance, reducing the likelihood of part damage due to rust. These characteristics make high-pressure aluminum die-cast parts suitable for components subjected to high loads and stress, such as engine blocks, transmission housings, and chassis components.
3. Complex Shape Capability:
High-pressure die casting is highly effective for mass-producing parts with complex and precise shapes. If the mold's precision is ensured, parts with intricate internal structures, curves, and thin walls can be produced with high accuracy. This allows for the integration of multiple parts into a single die-cast component, simplifying assembly processes and reducing production costs. It also increases design freedom, allowing for complex shapes that improve aerodynamic performance or differentiate designs.
4. High Productivity and Cost-Effectiveness:
High-pressure die casting is a very rapid production process. Large quantities of parts can be produced in a short time, making it suitable for mass production and leading to cost reductions. The use of precise molds minimizes the need for post-machining, further reducing additional processing costs. This cost-effectiveness makes high-pressure aluminum die casting widely used in the automotive industry.
5. Precise Dimensions and Excellent Surface Finish:
Because high-pressure die casting uses high-precision molds to form parts, dimensional accuracy is very high. Additionally, the molten aluminum conforms closely to the mold surface during solidification, resulting in parts with an excellent surface finish. This helps reduce the need for additional surface treatment processes, further lowering production costs.
6. Wide Range of Applications:
High-pressure aluminum die casting can be applied to produce various automotive parts. Typical examples include engine blocks, cylinder heads, transmission housings, oil pans, pump housings, chassis components, and structural parts. Recently, high-pressure aluminum die casting has also been actively applied to battery cases and motor housings for electric vehicles.
7. Thin-Wall Casting:
The high pressure used in this process allows for the creation of thin-walled castings, which further contributes to weight reduction without sacrificing structural integrity. This is particularly important for body and structural components where minimizing weight is crucial.
8. Integration and Consolidation:
As mentioned earlier, high-pressure die casting enables the integration of multiple parts into a single casting. This reduces the number of individual components, fasteners, and assembly operations, leading to cost savings, improved structural rigidity, and simplified logistics.
9. Recyclability:
Aluminum is a highly recyclable material, making high-pressure aluminum die casting a more sustainable manufacturing process. Recycled aluminum can be used to produce new parts, reducing the demand for primary aluminum production and its associated environmental impact.
10. Tight Tolerances and Repeatability:
The process offers excellent repeatability, ensuring consistent part quality and tight tolerances. This is crucial for automotive applications where precise fit and function are essential.
HPDC Automotive Parts Lists Examples:
Transmission Related:
 Engine mounting |  Integral engine mounting |
 Integral crossbeam |  Suspension strut bracket for SUVs |
Body Related:
 Door frame |  High-pressure die-casting nodes of the A-pillar |
 Gearbox crossbeams |  Inner door panels |
 Rear lid frames |  Side door panel |
 Housing for vibration dampers |  Steering wheel from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications" |
 Side door cast nodes |  Hinge and latch door panels |
Technical Resource For Automotive
Development of creep-resistant magnesium casting alloys for high temperature automotive applications
Impact behaviour of A356 alloy for low-pressure die casting automotive wheels
50 Years of Foundry-Produced Metal Matrix Composites and Future Opportunities
New Die Casting Alloy with High Ductility in As Cast State for Automotive Structural Components
Modeling alloy and energy utilization in high volume die casting
![Figure 1. Ashby diagrams used for material selection: ferrous metal alloys are represented in green, non-ferrous metal alloys in purple and red, plastics in blue, and composite materials with both plastic and metal matrices in brown and orange. The black lines are the maximum deterioration of parameters [53].](https://castman.co.kr/wp-content/uploads/image-847-245x300.webp)
Optimizing Lightweight Material Selection in Automotive Engineering: A Hybrid Methodology Incorporating Ashby’s Method and VIKOR Analysis
Analysis on the Development of Light-Weight Automobile Body
Layout Design and Die Casting Using CAE Simulation for Household Appliances
Evaluation of Thermal Stability and Its Effect on the Corrosion Behaviour of Mg-RE Alloys Processed by High-Pressure Torsion
![Figure 2. Use of magnesium-based materials in the automotive industry. Reproduced with permission from Sankaranarayanan, S. and M. Gupta (2021). “Emergence of god’s favorite metallic element: Magnesium based materials for engineering and biomedical applications.”; published by Elsevier, 2021 [54].](https://castman.co.kr/wp-content/uploads/image-820-300x203.webp)
Applications of Magnesium and Its Alloys: A Review
![Figure 9. Baseline part and demonstration part geometry (reproduced with permission from Reference [279]; copyright © 2024, The Minerals, Metals & Materials Society).](https://castman.co.kr/wp-content/uploads/image-803-300x200.webp)
Current Trends in Metallic Materials for Body Panels and Structural Members Used in the Automotive Industry 2024
Optimization of Die casting process based on Taguchi approach
Life Cycle Environmental Impact of Magnesium Automotive Components
Eco-sustainable lightweight automotive part manufacturing: GHGs-free die casting of brake leverage prototype made of AZ91D-1.5CaO magnesium alloy
Magnesium and its alloys applications in automotive industry
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