Die casting has an important place in the automotive industry for several reasons. This technique provides an effective alternative to metal fabrication to reduce the weight of automotive parts and improve mileage without compromising quality. This makes it possible to create parts that are lighter, more robust and have thinner walls. This is a huge contribution to the automotive industry.
In this article, we will discuss the advantages of die casting in automotive parts manufacturing and its application.
The advantages of using die casting in automotive parts manufacturing.
In recent years, automakers have focused on different techniques to make vehicles lighter, while maintaining durability. Die casting has many advantages in this direction, and has thus established itself as a valuable manufacturing technique for creating robust and lightweight automobile parts thanks to the materials used in this process, mainly aluminum, zinc and magnesium.
Below are the main advantages of die casting for manufacturing automotive parts:
Manufacturing of lightweight parts
Fuel economy is an important factor for automakers as there is increasing pressure to create more efficient vehicles. To achieve this objective, the use of aluminum is a valuable material thanks to the properties it possesses. Automotive manufacturers are therefore relying on the use of aluminum die casting to meet the new challenges presented by the automotive industry.
Aluminum is a lightweight metal with an excellent strength-to-weight ratio. As a result, it is the main metal used for casting engine parts and wheels. By ensuring the quality of external and internal components, manufacturers are now producing lighter and safer vehicles.
Increased automation and flexibility
Automotive die casting has become such an important manufacturing process that the technologies related to it are becoming more and more advanced. Die casting is getting more effective and productive thanks to automation, which ensures the creation of higher numbers of automotive die cast parts.
Additionally, die casting makes it possible to produce parts with unique designs, complex shapes and sizes that can be easily installed on vehicles.
Increased sustainability of parts
Die casting for automotive parts is an eco-friendly manufacturing process, so all the parts that are manufactured through this process are sustainable vehicle parts. The materials used for these parts can be recycled which makes them even more valuable, as it is the case with aluminium which can be recycled indefinitely.
The main processes used in die casting.
For the manufacture of automotive parts by die casting, there are two basic processes which will be chosen based on the requirements in terms of material, size, geometry and complexity. Indeed, many metals can be used to produce parts by die casting. However, the most common materials are aluminum, zinc and magnesium because they have unique advantages and ideal applications.
Hot die casting
The hot chamber die casting process, also called hot die casting, is ideal for materials with lower melting points, such as zinc and magnesium. The process is as follows: the metal will heat until it melts. A hydraulic piston will force the molten metal into the die cavity. The molten metal is then held under pressure in the cavity until it solidifies.
This process is only cost-effective for high-volume productions. We also note a low fluidity of the metal, thus limiting the complexity of the products.
Cold die casting
Cold chamber die casting involves pouring molten metal into the firing sleeve of the injection cylinder. After casting, a hydraulic piston forces the molten metal into the mold cavity without heating the sleeve. Since there is no heat, the process is called cold die casting. It is an ideal process for high melting point aluminum alloys.
This process offers great dimensional precision to the parts. It produces higher strength auto parts and denser metal castings due to the increased pressure. The process is easy to perform and requires low maintenance costs. However, the cycle time is slower than the hot chamber process due to the transfer process. There are also high levels of contaminants that can affect the quality of final automotive parts.
Automotive parts produced using die casting.
As previously stated, die casting can produce parts with unique designs, complex shapes and sizes. Therefore, there are a wide variety of applications of die casting to produce several types of automotive parts, including:
- Engine parts, e.g., cylinder head and gas engine parts
- Electronic covers for gearbox, motors, shade poles, etc.
- Fuel intake parts
- Air-conditioning systems
- Retractor spools for seatbelts
- Transmission and chassis components
- Durable power steering and braking systems
In conclusion, die casting allows you to create lightweight, high-quality parts. Its influence in the production of automobile parts has increased considerably as the industry faces new challenges, particularly environmental ones. Manufacturers can now meet industry standards without compromising engine quality and efficiency.
Comentários