Automotive integrated die casting process

- 2022-07-14-

What is integrated die casting?

Die-casting technology is a special casting technology. At present, die-casting aluminum alloy products account for about 54% to 70% of aluminum for automobiles. Integrated die-casting technology is a new revolution in die-casting technology. By redesigning multiple independent parts that need to be assembled in the original design, and using a super-large die-casting machine to die-cast at one time, complete parts can be directly obtained to realize the original function.

Compared with traditional automobiles, what are the advantages of one-piece die-casting automobiles?

1. Improve production efficiency
The data shows that a large-scale integrated die-casting machine can produce 1,000 castings a day in less than two minutes, while the traditional process of stamping and welding 70 parts to assemble a component takes at least two hours.
2. Reduce weight and improve battery life
Lightweight is one of the important means for electric vehicles to increase the cruising range. It can also help fuel vehicles reduce fuel consumption. At the same time, lightweighting will also improve acceleration, braking, and handling stability. According to the "Technical Roadmap 2.0 for Energy Saving and New Energy Vehicles" issued by the Chinese Society of Automotive Engineering, by 2025, the lightweight level of my country's fuel vehicles will be increased by 10% compared with 20 years, and the lightweight level of new energy vehicles will be improved compared with 20 years. 15%.
3. Reduce costs
The application of integrated die-casting technology can reduce production costs, land costs, and labor costs. According to Tesla's practice, the manufacturing cost has dropped by 40% compared to the original.

What are the technical barriers to integrated die casting?

1. Materials: The integrated die-casting technology relies on heat-free aluminum alloy materials.
2. Equipment: Integrated die-casting has high requirements on the clamping force of the die-casting machine, and the die-casting machine has technical barriers for custom design and development and relatively high capital expenditure.
3. Process: Since the integrated die-casting technology is in its infancy, it is necessary for the die-caster to have rich experience and technical accumulation in the production process to ensure the yield of mass production.
4. Mould: integrated die-casting parts have complex structure, high manufacturing cost and long preparation period, which put forward higher requirements for the production of die-casting moulds.

Why is integrated die casting a development trend?

①Reduce weight: In the context of dual carbon, lightweight is a major trend in the development of the automotive industry. The application of integrated die casting contributes to the realization of lightweight.
②Improve efficiency: Compared with the existing production process, integrated die casting improves the production efficiency by simplifying the production process and improving the tact.
③Reduce costs: The application of integrated die-casting technology can reduce production, land, labor and other costs. Tesla rate applied the integrated die-cast rear floor, and the manufacturing cost was reduced by 40% compared with the original.