{"id":1995,"date":"2025-03-04T18:38:51","date_gmt":"2025-03-04T10:38:51","guid":{"rendered":"https:\/\/www.hexinmusu.com\/?p=1995"},"modified":"2025-03-04T18:44:56","modified_gmt":"2025-03-04T10:44:56","slug":"about-detail-54","status":"publish","type":"post","link":"https:\/\/www.hexinmusu.com\/en\/about-detail-54.html","title":{"rendered":"The application of automotive aluminum die casting lightweight technology path and practice exploration"},"content":{"rendered":"

\u200cAuthor: Senior Engineer, Ningbo Hersin Molding Co., Ltd (20 years experience in casting industry)<\/strong>\u200c<\/p>\n\n\n\n

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\"Automotive<\/figure>\n\n\n\n

1. Strategic value of aluminum alloy materials<\/h2>\n\n\n\n

With the deepening of global carbon emission reduction policies, the automotive industry is undergoing a structural transformation from \"steel-based\" to \"multi-material synergy\". Aluminum alloys, by virtue of theirLow density properties<\/strong>together withRecyclable Advantage<\/strong>Aluminum alloy die casting has become the core breakthrough in realizing the light weight of the whole vehicle. In the architecture of new energy models, aluminum alloy die casting has penetrated into the body frame, three electric systems, chassis structure and other key areas, forming a lightweight solution covering the whole body.<\/p>\n\n\n\n

Current industrial practice shows that the use of modular die-casting technology can significantly reduce the number of parts and assembly complexity. Typical cases show that through the structural integration and process innovation, a model of body-in-white successfully realized material weight reduction and production line efficiency synchronization. This technology path not only responds to the demand for energy saving and emission reduction, but also creates significant economic benefits for car manufacturers.<\/p>\n\n\n\n

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2, aluminum die casting technology system<\/h2>\n\n\n\n

2.1 Comparison of mainstream processes<\/h3>\n\n\n\n
Process Type<\/th>Technical Advantages<\/th>Typical Application Scenarios<\/th><\/tr><\/thead>
High Pressure Die Casting<\/td>High-precision thin-wall molding<\/td>Motor housings\/gearbox components<\/td><\/tr>
Low-pressure casting<\/td>Low porosity and high densification<\/td>Suspension system\/wheel assembly<\/td><\/tr>
Gravitational casting<\/td>Near-net-shape forming of thick-walled parts<\/td>Chassis components\/steering knuckles<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

pass (a bill or inspection etc)Vacuum Assisted Technology<\/strong>together withIntelligent temperature control system for molds<\/strong>Modern die casting processes have broken through traditional wall thickness limitations to enable more complex lightweight structural designs25.<\/p>\n\n\n\n

2.2 Direction of technological innovation<\/h3>\n\n\n\n
    \n
  • \u200cIntegral molding<\/strong>: Consolidate multiple parts into a single component, reducing joining processes and material redundancy.<\/li>\n\n\n\n
  • \u200cComposite Process Development<\/strong>: Integrate casting and forging technology to improve the mechanical properties of key components.<\/li>\n\n\n\n
  • \u200cDigital Simulation<\/strong>: Optimize casting system design and reduce process development costs through CAE simulation.<\/li>\n<\/ul>\n\n\n\n
    \n\n\n\n

    3\u3001Industry application practice<\/h2>\n\n\n\n

    3.1 Structural innovations in the bodywork<\/h3>\n\n\n\n

    All-aluminum body technology throughTopology optimization design<\/strong>together withHigh Toughness Alloys Applications<\/strong>In addition, the weight of the body-in-white has been significantly reduced under the premise of ensuring collision safety. Typical models have realized the proportion of aluminum die-casting parts in the car body is more than half, which significantly improves the range and handling performance.<\/p>\n\n\n\n

    3.2 Upgrading of the triboelectric system<\/h3>\n\n\n\n

    Key components such as the drive motor housing are made ofThin-wall die casting solutions<\/strong>The new product is designed to meet the needs of sealing and protection while breaking through traditional weight limitations and helping to improve energy efficiency.<\/p>\n\n\n\n

    \n\n\n\n

    4. Challenges of industry chain synergistic development<\/h2>\n\n\n\n
    technological bottleneck<\/th>Innovative Solutions<\/th>Synergies<\/th><\/tr><\/thead>
    Oversized member deformation control<\/td>Development of a multi-dimensional compensation mold system<\/td>Improved stability of dimensional accuracy<\/td><\/tr>
    Material recycling rate<\/td>Construction of an integrated spectral sorting and smelting device<\/td>Reducing carbon emission targets<\/td><\/tr>
    process stability<\/td>Deployment of online monitoring and machine learning systems<\/td>Realize real-time defect alerts<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

    Leading industry players are passingIntelligent Die Casting Island<\/strong>The construction has raised the precision of process parameter control to a new order of magnitude. After the introduction of a full-process MES system at a production base, the fluctuation of key quality indicators narrowed significantly.<\/p>\n\n\n\n

    5. Future direction of technological evolution<\/h2>\n\n\n\n
      \n
    1. \u200cUltra-large die-casting equipment<\/strong>: Promote the popularization of modular production of front pods\/rear sumps.<\/li>\n\n\n\n
    2. \u200cdigital twin<\/strong>: Build virtual debugging platform to shorten new product development cycle.<\/li>\n\n\n\n
    3. \u200cLow Carbon Preparation Systems<\/strong>: Improving the recycled aluminum supply chain to achieve green manufacturing.<\/li>\n<\/ol>\n\n\n\n

      Current technological breakthroughs have extended toMaterial-Process-Equipment Co-Innovation<\/strong>At the level of a new die-casting production line, a new type of energy recovery system, successfully reduced the unit energy consumption to the industry's advanced level.<\/p>\n\n\n\n

      \n\n\n\n

      concluding remarks<\/h2>\n\n\n\n

      Automotive aluminum die casting lightweight has developed from local substitution to systematic engineering solutions. As a casting enterprise with the ability to serve the whole industry chain, we will continue to plowingMaterial modification<\/strong>.process integration<\/strong>together withintelligent manufacturing<\/strong>field, providing technical support for the green transformation of the global automotive industry.<\/p>","protected":false},"excerpt":{"rendered":"

      Author: Senior Engineer of Ningbo Hexin Molding Co., Ltd (20 years of experience in casting industry) 1. Strategic Value of Aluminum Alloy Materials With the deepening of global carbon emission reduction policy, the automotive industry is experiencing a structural transformation from \"steel-based\" to \"multi-material synergy\". Aluminum alloy materials have become the core breakthrough in realizing vehicle lightweighting by virtue of their low-density characteristics and recyclable advantages. In the architecture of new energy models, aluminum alloy die castings have penetrated into the body frame, three electric systems, chassis structure and other key areas, forming a lightweight solution covering the whole body. Current industrial practice shows that the use of modular die casting technology can significantly reduce the number of parts and assembly complexity. Typical cases show that through structural integration and process innovation, a model of body-in-white successfully realized material reduction ...<\/p>","protected":false},"author":1,"featured_media":1996,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":[],"categories":[21],"tags":[49],"class_list":["post-1995","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-about-news","tag-die-casting"],"_links":{"self":[{"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/posts\/1995","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/comments?post=1995"}],"version-history":[{"count":0,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/posts\/1995\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/media\/1996"}],"wp:attachment":[{"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/media?parent=1995"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/categories?post=1995"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/tags?post=1995"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}