Aluminum High-Pressure Die Casting (HPDC) for Automotive Parts

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 braceFrontal cross braceRHT folding levers
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
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.

General classification of the most common aluminium automotive parts
General classification of the most common aluminium automotive parts

HPDC Automotive Parts Lists Examples:

Transmission Related:

Engine mounting
Engine mounting
Integral engine mountingIntegral engine mounting
Integral crossbeam
Integral crossbeam
Suspension strut bracket for SUVs
Suspension strut bracket for SUVs

Body Related:

Door frame
Door frame
High-pressure die-casting nodes of the A-pillar
High-pressure die-casting nodes of the A-pillar
Gearbox crossbeams
Gearbox crossbeams
Inner door panels
Inner door panels
Rear lid frames
Rear lid frames
Side door panel
Side door panel
Housing for vibration dampersHousing for vibration dampersSteering wheel
Steering wheel
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"
Side door cast nodesSide door cast nodesHinge and latch door panels
Hinge and latch door panels

Technical Resource For Automotive

Fig. 1 Schematic of low-pressure die cast with LS for A356 alloy wheels

Microstructure and Properties of A356 Alloy Wheels Fabricated by Low-Pressure Die Casting with Local Squeeze

This introduction paper is based on the paper "Microstructure and Properties of A356 Alloy Wheels Fabricated by Low-Pressure Die Casting ...
Fig. 1 High-pressure die-cast specimens

Metallurgical Assessment of Novel Mg-Sn-La Alloys Produced by High-Pressure Die Casting

This introduction paper is based on the paper "Metallurgical Assessment of Novel Mg-Sn-La Alloys Produced by High-Pressure Die Casting" published ...
Fig.1. Cause and effect diagram (Ishikawa diagram) for casting porosity

Optimization of process parameters of High Pressure Die Casting process for ADC12 Aluminium alloy using Taguchi method

This introduction paper is based on the paper "[Optimization of process parameters of High Pressure Die Casting process for ADC12 ...
Permanent Mold Casting: An Excellent Manufacturing Method for Automotive Components

Permanent Mold Casting: An Excellent Manufacturing Method for Automotive Components

This introduction paper is based on the paper "Permanent Mold Casting" Excellent Casting Method for Manufacture of Automotive Components" published ...
FIG. 2 Door and window frames for a German sports car (Photo: Georg Fischer AG). Telai di portiere e finestrini di un’automobile sportiva tedesca (Photo: Georg Fischer AG).

The tool steel producer’s contribution to successful die casting of structural components

This introduction paper is based on the paper "The tool steel producer's contribution to successful die casting of structural components" ...
Fig. 1. The components of intermetallic phases examined using XRD and TEM in the Mg4LaxAl (x ¼ 08, wt.%) alloys fabricated by gravity die casting. The purple dotted lines correspond to the critical Al/La ratio for the formation of certain simplex intermetallic phase, and the dotted gray area corresponds to the Al/La range where only Mg12La phase forms. (For interpretation of the references to color in this figure legend, the reader is referred to the Web version of this article.)

Developing a die casting magnesium alloy with excellent mechanical performance by controlling intermetallic phase

This article introduces the paper "Developing a die casting magnesium alloy with excellent mechanical performance by controlling intermetallic phase". 1 ...
High-pressure die-cast (HPDC) aluminium alloys for automotive applications

High-pressure die-cast (HPDC) aluminium alloys for automotive applications

This article introduces the paper ['High-pressure die-cast (HPDC) aluminium alloys for automotive applications'] presented at the ['Advanced materials in automotive ...
Figure 1: Inner side of the moving die (a) and the geometry with four test cases two-holes, steps, threecan and u-profiles (b) and the shown in a)

Combined Defect Prediction for Large-Area Die-Cast Components Using High-Resolution Multi-Phase Simulation

This article introduces the paper "Combined defect prediction for large-area die-cast components using high-resolution multi-phase simulation". 1. Overview Title: Combined ...
Figure A. Outer rotor induction motor mesh operation and 2D FEA

High-Efficiency Outer Rotor Induction Machine Design for Diverse Industrial Applications

The content of this introduction paper is based on the article "For different industrial applications: Outer rotor and low speed ...
Fig. 4. Output Power vs Speed

Performance Enhancement of BLDC Motor for Electric Vehicle Applications

The content of this introduction paper is based on the article "Performance Enhancement of BLDC Motor for Electric Vehicle Applications" ...
Figure 3. Structure of rotor slots and tooth

Efficiency Improvement of Induction Motors via Rotor Slot and Tooth Structure Optimization

The content of this introduction paper is based on the article "Efficiency improvement of induction motors based on rotor slot ...
Fig.1 The growth trend of magnesium alloy in China’s automobile industry

Application of Automobile Lightweight Alloys and the Development of its Die-Casting Technology

This article introduces the paper "Application of Automobile Lightweight Alloys and the Development of its Die-Casting Technology". 1. Overview: Title: ...
Figure 5: Cold flow surface defects at final filling positions.

Experimental and Theoretical Studies on the Effect of Die Temperature on the Quality of the Products in High-Pressure Die-Casting Process

This introductory paper is the research content of the paper "Experimental and Theoretical Studies on the Effect of Die Temperature ...

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