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

Figure 7. Cross Section Temperature Profiles in Natural Convection for assembly in Figure 2. (a) Top view and (b) Side view. Temperature range shown is 60 to 100°C.

Thermal Management of Bright LEDs for Automotive Applications

This introduction paper is based on the paper "Thermal Management of Bright LEDs for Automotive Applications" published by "7th. Int ...
Figure 53 : as built Z sample fracture surface magnitude 1,50K,x

Selective laser melting aluminum alloys for automotive component

This introduction paper is based on the paper "Selective laser melting aluminum alloys for automotive component" published by "Politecnico di ...
Fig: 1.0 Nonfilling defect

Minimise the Nonfilling defect in the high pressure casting process component for an automotive application with metal flow simulation analysis

This introduction paper is based on the paper "Minimise the Nonfilling defect in the high pressure casting process component for ...
Fig. 3. SKD61 steel salt core mold.

Improving the Mechanical Properties of Salt Core through Reinforcing Fibers

This introduction paper is based on the paper "Improving the Mechanical Properties of Salt Core through Reinforcing Fibers" published by ...
High-Temperature Mechanical Properties of NaCl–Na2CO3 Salt-Mixture Removable Cores for Aluminum Die-Casting

High-Temperature Mechanical Properties of NaCl­Na2CO3 Salt-Mixture Removable Cores for Aluminum Die-Casting

This introduction paper is based on the paper "[High-Temperature Mechanical Properties of NaCl-Na2CO3 Salt-Mixture Removable Cores for Aluminum Die-Casting]" published ...
Figure 2 Effective stress contours vs. Time

DEVELOPMENT AND APPLICATION OF CASTING DISTORTION & COMPENSATION TECHNOLOGY BASED ON AUTOMATIC ITERATION METHOD

This introduction paper is based on the paper "DEVELOPMENT AND APPLICATION OF CASTING DISTORTION & COMPENSATION TECHNOLOGY BASED ON AUTOMATIC ...
Fig.12. Caluclated thermal steady state in cooper cage

Parametrization of the Thermal Model of Induction Motor with Outer Rotor for High Power Density Applications

The content of this introduction paper is based on the article "Parametrization of the thermal model of induction motor with ...
Influence of Super Large Single Piece Die Casting ProductiontoAutomotive Industry

Influence of Super Large Single Piece Die Casting Production to Automotive Industry

This introduction paper is based on the paper "Influence of Super Large Single Piece Die Casting Production to Automotive Industry" ...
Fig. 3. Quarter section of an induction motor

Analytical Model for Induction Motors Rotor Slot Parametric Design Performance Evaluation

The content of this introduction paper is based on the article "An Analytical Model of Induction Motors for Rotor Slot ...
Fig. 11. Sectional View of Lower End Ring

Quality Evaluations of Induction Motor Rotors during Die Casting Process

This introduction paper is based on the paper "Quality Evaluations of Induction Motor Rotors during Die Casting Process" published by ...
Fig. 1. The flowchart of the manufacturing process

Development of Water-Soluble Composite Salt Sand Cores Made by a Hot-Pressed Sintering Process

This introduction paper is based on the paper "Development of Water-Soluble Composite Salt Sand Cores Made by a Hot-Pressed Sintering ...
Figure 13. Surface of the SA-sample analyzed with the confocal laser scanning microscope. The top images show the sample’s surface before coming into contact with molten salt and the bottom two images show the surface after molten salt contact. Next to the laser images (a,c), the corresponding optical images are displayed (b,d). No significant change in the surface can be seen. The results of the confocal laser scanning microscopy for the other two droplets do not differ qualitatively.

Influence of Salt Support Structures on Material Jetted Aluminum Parts

This introduction paper is based on the paper "Influence of Salt Support Structures on Material Jetted Aluminum Parts" published by ...

Design with White Light-Emitting Diodes for an Automotive Low-Beam Projector Headlamp

This introduction paper is based on the paper "Design with White Light-Emitting Diodes for an Automotive Low-Beam Projector Headlamp" published ...
Figure 3. Buckling analysis model: boundary condition and load cases.

Experimental and Numerical Study of an Automotive Component Produced with Innovative Ceramic Core in High Pressure Die Casting (HPDC)

This introduction paper is based on the paper "Experimental and Numerical Study of an Automotive Component Produced with Innovative Ceramic ...
Figure 1. Crank case specimen produced with the HPDC process.

Minimizing the casting defects in high-pressure die casting using Taguchi analysis

This introduction paper is based on the paper "Minimizing the casting defects in high-pressure die casting using Taguchi analysis" published ...

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