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.
    • Durability and complex shape parts:
      • Belt, muffler, carburetor, fuel tank, water tank, fan, oil seal, radiator, filter.

2. Powertrain Accessories

  • Precision gears and shafts:
    • Gears, intermediate shaft, drive shaft assembly, drive shaft flange, synchronizer ring.
    • Complex structural components:
      • Transfer case, clutch disc, flange, planetary gear, wheel carrier.
RHT folding levers
RHT folding levers
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"
Frontal cross brace
Frontal cross brace
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"

3. Brake System Accessories

  • Components requiring durability and heat management:
    • Brake disc, brake drum, brake master cylinder, brake cylinder.
    • Precision components:
      • ABS-ECU controller, brake pedal assembly, brake chamber, vacuum booster.

4. Steering System Accessories

  • Steering gear, steering knuckle, power pump.

5. Suspension and Axle Accessories

  • Parts requiring weight reduction:
    • Rear axle, half axle, balance weight.

6. Electrical and Instrumentation Accessories

  • Precision and heat-dissipation-critical parts:
    • Ignition module, ignition coil, alternator housing.

7. Automotive Lighting and Exterior Parts

  • Complex exterior components:
    • Headlight housing, decoder housing, decorative automotive exterior parts.

8. Body and Safety Components

  • Wiper housing, airbag casing, instrument panel housing.

9. Maintenance Equipment and Others

  • Precision equipment casings and tool housings.

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
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"

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.

Hinge and latch door panels
Hinge and latch door panels
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"

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:

HPDC nodes of the Lamborghini Gallardo Spyder
HPDC nodes of the Lamborghini Gallardo Spyder
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"

Engine Related:

  1. Engine Block (partial or complete)
  2. Cylinder Head (partial or complete)
  3. Oil Pan
  4. Intake Manifold (sections)
  5. Exhaust Manifold (sections)
  6. Water Pump Housing
  7. Valve Cover
  8. Camshaft Housing
  9. Crankcase Vent Housing
  10. Oil Cooler Housing
  11. Turbocharger Housing (sections)
  12. Supercharger Housing (sections)
  13. Engine Mount Bracket
  14. Throttle Body Housing (sections)
  15. Intake Manifold Assembly (sections)
  16. Accelerator Pedal Assembly (sections)
  17. Ignition Coil Bracket
  18. Spark Plug Wire Guide
  19. Sensor Bracket
  20. Belt Tensioner Housing
Engine mounting
Engine mounting
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"
Integral engine mounting
Integral engine mounting
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"

Transmission Related:

  1. Transmission Housing (sections)
  2. Transmission Case
  3. Gear Selector Housing
  4. Torque Converter Housing (sections)
  5. Oil Pump Housing
  6. Valve Body Housing (sections)
  7. Shaft Bearing Housing (sections)

Chassis & Suspension Related:

  1. Suspension Arm
  2. Steering Knuckle
  3. Wheel Hub
  4. Brake Caliper Bracket
  5. Stabilizer Bar Mount
  6. Control Arm
  7. Cross Member
  8. Subframe (sections)
  9. Front End Module (sections)
  10. Rear End Module (sections)
  11. Steering Gear Housing (sections)
  12. Rack End Housing (sections)
  13. Shock Absorber Mount
Suspension strut bracket for SUVs
Suspension strut bracket for SUVs
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"
Integral crossbeam
Integral crossbeam
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"
Shock tower
Shock tower
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"

Body Related:

  1. Door Handle
  2. Side Mirror Housing
  3. Window Regulator Housing
  4. Rearview Mirror Housing
  5. Roof Rail (sections)
  6. Bumper Bracket
  7. Grille Frame (sections)
  8. Headlamp Housing (sections)
  9. Taillamp Housing (sections)
  10. Mirror Adjustment Housing
  11. Door Check Plate
  12. Door Hinge Cover
  13. Wiper Arm
  14. Sunroof Frame (sections)
  15. Roof Panel (sections)
  16. Trunk Hinge
  17. Trunk Latch
  18. Hood Hinge
  19. Hood Latch
  20. Side Skirt
High-pressure die-casting nodes of the A-pillar
High-pressure die-casting nodes of the A-pillar
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"
Door frame
Door frame
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"
Inner door panels
Inner door panels
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"
Gearbox crossbeams
Gearbox crossbeams
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"
Side door panel
Side door panel
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"
Side door cast nodes
Side door cast nodes
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"
Rear lid frames
Rear lid frames
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"

Electrical/Electronic Related:

  1. Battery Tray
  2. Fuse Box Housing
  3. Control Unit Housing (sections)
  4. Motor Housing (sections)
  5. Sensor Housing (sections)
  6. Wiring Harness Bracket
  7. Relay Bracket
  8. ECU Mounting Bracket

HVAC Related:

  1. A/C Compressor Bracket
  2. Heater Core Housing
  3. Blower Motor Housing

Fuel System Related:

  1. Fuel Tank (sections)
  2. Fuel Pump Housing
  3. Fuel Rail (sections)
  4. Fuel Injector Bracket

Other:

  1. Seat Frame (sections)
  2. Steering Wheel Hub
  3. Pedal Bracket
  4. Foot Rest
  5. Center Console (sections)
  6. Glove Box (sections)
  7. Airbag Housing (sections)
  8. Seatbelt Buckle (sections)
  9. License Plate Bracket
  10. Windshield Washer Tank
  11. Windshield Wiper Motor Housing
  12. Wheel Assembly (certain components)
  13. Spring Seat
  14. Heat Exchanger Housing
  15. Hydraulic System Components (e.g., pump housing, valve body)
  16. Electric Power Steering Pump Housing
  17. Air Suspension Compressor Housing
  18. ADAS Sensor Bracket
  19. Radiator Tank (upper/lower)
  20. Intercooler Housing (sections)
  21. Oil Filter Housing
  22. Air Cleaner Housing (sections)
  23. Throttle Body Assembly (sections)
  24. Steering Column Housing (sections)
  25. Accelerator Pedal Assembly (sections)
Steering wheel
Steering wheel
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"
Housing for vibration dampers
Housing for vibration dampers
from "6 - High-pressure die-cast (HPDC) aluminium alloys for automotive applications"

Technical Resource For Automotive

Figure 5. Flow characteristics at different velocities of injection: : (a1–a6) 1.0 m/s, (b1–b6) 1.5 m/s

Study on the Influence of Injection Velocity on Hole Defects in Die-Cast Aluminum Alloy

This paper summary is based on the article "Study on the Influence of Injection Velocity on the Evolution of Hole ...
Figure 1. Structure of the vacuum die-cast equipment

Study on Microstructures and Properties of Al. Alloy Vacuum Die-Cast Parts

This paper summary is based on the article "Study on Microstructures and Properties of the Al. Alloy Vacuum Die-Cast Parts ...
Figure 13. The schematic diagrams of the ACSR Rheo-HPDC process (reprinted with permission from ref. [36], 2022, Elsevier).

Research Progress on Thermal Conductivity of High-Pressure Die-Cast Aluminum Alloys

This paper summary is based on the article Research Progress on Thermal Conductivity of High-Pressure Die-Cast Aluminum Alloys presented at ...
Figure 5. Results of constrained rod casting: (a) AA7075; (b) AA7068; (c) AA7055.

Development of Low-Pressure Die-Cast Al–Zn–Mg–Cu Alloy Propellers—Part I: Hot Tearing Simulations for Alloy Optimization

This paper summary is based on the article Development of Low-Pressure Die-Cast Al–Zn–Mg–Cu Alloy Propellers—Part I: Hot Tearing Simulations for ...
Figure 8. Developed Al-6Zn-2Mg-1.5Cu alloy propeller

Development of Low-Pressure Die-Cast Al-Zn-Mg-Cu Alloy Propellers Part II: Simulations for Process Optimization

1. Overview: Title: Development of Low-Pressure Die-Cast Al-Zn-Mg-Cu Alloy Propellers Part II: Simulations for Process OptimizationAuthor: Min-Seok Kim and Soonho ...
Fig. 4. Integrated magnesium door cast inner developed as part of a DOEsponsored project led by GM, right, and equivalent steel stamped door inner, left [10] (Copyright 2015 by IMA. Used with permission).

A review of magnesium die-castings for closure applications

1. Overview: Title: A review of magnesium die-castings for closure applications Author: J.P. Weiler Year of Publication: 2019 Journal/Conference: Journal ...
Figure 11. Micrographs of fractured (a) α-Al15(Fe,Mn,Cr)3Si2 particle and (b) β-Al5FeSi platelet after wear testing.

Designing Wear-Resistant Diecast AlSi9Cu3(Fe) Alloys for High-Temperature Components

This paper summary is based on the article [Design of Wear-Resistant Diecast AlSi9Cu3(Fe) Alloys for High-Temperature Components] published in the ...
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

1. Overview Title: Combined defect prediction for large-area die-cast components using high-resolution multi-phase simulation Authors: J. Jakumeit, Η Behnken, R ...
Fig. 1 Pictures of one of the better castings a and c die temperature 250 °C and injection velocity 2.0 m/s, and worst castings b and d die temperature 180 °C and injection velocity 1.3 m/s for AS31

Mechanical Properties and Deformation Behaviour of High-Pressure Die-Cast Magnesium-Aluminium Based Alloys

1. Overview: Title: Mechanical Properties and Deformation Behaviour of High-Pressure Die-Cast Magnesium-Aluminium Based Alloys Author: Hua Qian Ang (Vivian) Publication ...
Fig. 2. Improved part design

Magnesium Alloys and Applications in Automotive Industry

1. Overview: Title: Magnesium alloys and applications in automotive industry Author: Nima Khademian, Yaser Peimaei Publication Year: August 2021 Publishing ...
Figure 9 A part of Al die cast product where internal soundness was improved by the application of DHA-THERMO core pins

Paper Summary: High Thermal Conductivity Steel and its Application to Die Casting Tools

This paper summary is based on the article "High Thermal Conductivity Steel and its Application to Die Casting Tools" presented ...
Figure 2. EPMA micrograph and chemical element distribution maps of crept AA365 alloy at 373 K: Al, Mg, Fe, Si, Mn

Evaluation of Corrosion Behavior on Crept AlSi10MnMg (AA365) Alloy Produced by High-Pressure Die-Casting (HPDC)

This paper provides a detailed analysis of the corrosion behavior of crept AlSi10MnMg (AA365) alloy, a material widely used in ...
Fig.6 Fluid field simulation result

Fatigue behavior of magnesium alloy and application in auto steering wheel frame

This blog post summarizes the research paper titled "Fatigue behavior of magnesium alloy and application in auto steering wheel frame," ...
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

1. Overview: Title: Developing a die casting magnesium alloy with excellent mechanical performance by controlling intermetallic phase Authors: Fanzhi Meng, ...
Figure 1. Schematic illustration of the rheodiecasting (RDC) process.

Development of the Rheo-Diecasting Process for Mg-Alloys

This paper summary is based on the research article "Development of the Rheo-Diecasting Process for Mg-Alloys" by Z. Fan, S ...
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