Prototipagem rápida e fabricação sob demanda para
Automotive Industry

The aluminum alloy die-casting process for automotive parts includes melting the aluminum alloy, ladling it into a cold-chamber die casting machine, injecting it into the mold under high pressure, then opening the mold and ejecting the part after solidification​. This process offers short cycle times, high dimensional accuracy, and smooth surface finishes, suitable for mass production of automotive parts​.

Aluminum alloy die casting parts feature an excellent strength-to-weight ratio, which can significantly reduce vehicle mass, improve fuel efficiency, and extend driving range​. Additionally, aluminum alloys inherently offer good corrosion resistance and thermal conductivity, benefiting the performance of engine and heat-exchange components​.

The most common aluminum alloy grades include A380, A360, A383, and ADC12, with A380 being the first choice in the automotive industry due to its balanced mechanical properties and machinability​. In addition, Al-Si-Cu alloys are widely used in engine components to balance strength and heat resistance​.

Our design team utilizes specialized software for product development and mold flow analysis, ensuring designs meet production requirements. Through pre-production simulations, we optimize processes to reduce trial runs and improve yield.

When selecting materials, consider strength requirements, operational environment (e.g., corrosion and heat resistance), machinability, and cost. Refer to CastMold’s material guide to choose grades like AC-46500 or A380 for optimal strength-to-ductility ratios​. Also, pay attention to the effects of Cu and Mg content on corrosion resistance and mechanical properties​

The thermal conductivity of aluminum die cast parts can typically exceed 160 W·m⁻¹·K⁻¹, facilitating rapid heat dissipation in components like engine blocks and radiators, thereby enhancing thermal management efficiency and reliability​

Key cost factors include raw materials (aluminum alloy), mold fabrication and maintenance, production volume, cycle time, and secondary operations (machining, surface finishing)​. Optimizing mold design, enhancing production efficiency, and minimizing scrap rates are critical measures to control costs​.

Equipment commonly used for aluminum alloy die-casting automotive parts includes cold-chamber die casting machines, multi-station high-pressure injection systems, mold temperature controllers, and automated robotic arms​. Auxiliary equipment also comprises melting furnaces, trim presses, and in-line quality inspection systems to ensure production efficiency and part quality​.

You can optimize tooling design, suitably arrange gating systems and vents, and perform mold flow analysis early to reduce defects and improve yield. Additionally, implementing automated production lines and real-time monitoring systems enhances production stability and efficiency, reducing labor costs and scrap rates.

Common alloy grades for aluminum alloy die-casting automotive parts include A380, A360, and ADC12, with A380 widely used due to its excellent mechanical properties and machinability​. When selecting, one must also consider the alloy’s heat resistance, corrosion resistance, and castability to meet the specific requirements of components like engine blocks and transmission housings.

Key mold design considerations include optimizing the runner system, vents, and gate positions to ensure uniform melt flow and reduce defects like porosity and cold shuts​. You should also design appropriate draft angles and parting lines based on wall thickness distribution to facilitate demolding and extend mold life.

By implementing ISO 9001 and IATF 16949 quality management systems and deploying real-time online monitoring and automated inspection equipment during production, consistency and reliability of aluminum alloy die-casting automotive parts are ensured​. Additionally, regular mold maintenance, melt composition checks, and analysis of injection pressure profiles can effectively prevent common defects like cracks, shrinkage porosity, and inclusions​

Common post-processing techniques for aluminum alloy die-casting automotive parts include deburring, drilling, and machining; surface finishing processes include anodizing, electroplating, sandblasting, and powder coating to enhance corrosion resistance and appearance​. Before machining and finishing, shot peening can be applied to improve fatigue life and surface hardness of the parts.

We are well-versed in PPAP processes and can prepare complete Production Part Approval documentation, guiding clients through the review procedures.

Oferecemos prazos de entrega flexíveis de 2 a 10 semanasO sistema de gerenciamento de projetos é um sistema de gerenciamento de projetos, adaptado à complexidade do projeto e aos requisitos do cliente. Por meio da confirmação de projetos paralelos e de soluções de fabricação modular, os projetos padrão podem ser entregues em em até 2 semanascom projetos complexos concluídos dentro de Máximo de 10 semanas.