Product Name: Multi-Field Adaptable Precision Die Castings
(Aluminum Alloy/Magnesium Alloy Series)
1. Product Positioning and Core Value
Against the backdrop of the current transformation of the high-end
manufacturing industry towards "lightweight, integrated, and
efficient" development, this series of multi-field adaptable
precision die castings, relying on a mature high-pressure die
casting technology system, has become a key structural support
component in five core fields: automotive, high-speed rail,
electronic communications, aerospace, and consumer goods. Its core
value lies in breaking the limitations of traditional manufacturing
through technological innovation—it can not only achieve the
precise molding of micro electronic heat dissipation components
(such as 5G base station chip heat sinks) but also complete the
integral casting of extra-large integrated automotive body parts
(such as the rear floor of new energy vehicles). Through the
"one-time molding" process, it significantly reduces subsequent
processing links, helping end enterprises cut assembly costs by
more than 30%. At the same time, it finds the optimal balance
between weight control and structural strength, truly realizing the
dual goals of "weight reduction & efficiency improvement and
performance upgrading".
From the perspective of market demand, whether it is the demand for
breaking through the cruising range of new energy vehicles, the
dual requirements for miniaturization and heat dissipation of 5G
equipment, or the strict standards for material lightweight and
reliability in the aerospace field, this series of die castings can
accurately respond through customized solutions. It serves as a key
link connecting upstream material innovation and downstream
equipment upgrading, providing solid structural component support
for the high-end transformation of various industries.
2. Core Technologies and Performance Highlights
1. Dual Advantages of Lightweight and High Strength
In terms of material selection, this series of products carefully
selects two types of high-performance lightweight alloys: First,
the aluminum alloy series, with models 380 and 413 as the core.
These alloys have good casting fluidity and mechanical strength,
making them suitable for mass production of automotive chassis
components, electronic equipment housings, etc. Second, the
magnesium alloy series, focusing on models AZ91D and AM60. Its
density is only 2/3 that of aluminum alloy and 1/4 that of steel,
making it one of the metal materials with the most prominent
lightweight effect. It is particularly suitable for aerospace, UAVs
and other fields sensitive to weight. Through the application of
these two types of materials, the product can achieve a weight
reduction of 30%~50% compared with traditional steel components,
and the magnesium alloy products can further reduce weight by more
than 20% on this basis, perfectly adapting to the urgent demand for
"lightweight" in various industries.
To solve the problem of insufficient strength that may be caused by
"lightweight", the product adopts a high-vacuum die casting
process—during the die casting process, professional vacuum
equipment is used to extract air from the mold cavity, maintaining
the vacuum degree in the cavity above 95%. This effectively reduces
internal defects such as air holes and shrinkage porosity in the
casting, strictly controlling the porosity within 1%. At the same
time, for key components that need to withstand high-frequency
vibrations, such as high-speed rail bogies and automotive chassis,
insert die casting technology is additionally adopted.
High-strength steel parts, carbon fiber reinforced parts, etc. are
embedded into the mold cavity in advance and cast integrally with
the die casting body in one go. This increases the local strength
of the component by more than 40% and extends the fatigue life by
3~5 times, ensuring stable performance even under long-term harsh
working conditions.
2. Precision Molding and Integrated Manufacturing Capability
In terms of precision molding, relying on advanced CNC die casting
equipment and precision mold technology, this series of products
has achieved extremely high dimensional control accuracy—the linear
dimensional tolerance can be stably controlled within ±0.1mm, and
the geometric tolerance (such as parallelism, perpendicularity) is
controlled within ±0.05mm, fully meeting the strict requirements
for dimensional consistency of precision components such as 5G base
station heat sinks and mobile phone middle frames. What is more
noteworthy is its thin-wall molding capability. By optimizing die
casting process parameters (such as injection speed, mold
temperature, and pressure holding time), the minimum wall thickness
of the casting can be reduced to 0.5mm, and there are no defects
such as cracks or deformation in the thin-wall area. This
technological breakthrough provides key support for the
"miniaturization and thinning" of electronic equipment. For
example, the middle frame of a well-known mobile phone brand made
of this series of die castings reduces the thickness by 15% while
still maintaining sufficient anti-drop strength.
In the field of integrated manufacturing, the technical advantages
of this series of products are even more significant. In
traditional manufacturing, large structural components (such as
automotive body floors) often require 70~100 scattered parts to be
assembled through welding, bolt connection, etc. This not only
involves cumbersome processes and low production efficiency but
also easily leads to reduced structural stability due to too many
welding points and connection points. However, through the
cooperation of extra-large die casting molds (with a maximum mold
size of up to 5m×3m) and high-tonnage die casting machines (with a
clamping force of over 6,000 tons), this series of die castings can
cast these scattered parts into an integral component in one go.
For example, referring to the manufacturing plan of Tesla Model Y's
rear floor, this series of products can achieve the breakthrough of
"integrating more than 70 parts into one", reducing more than 90%
of welding points, increasing the structural strength of the
component by 25%, and shortening the production cycle from 2 hours
(traditional process) to 30 minutes, significantly improving
production efficiency.
3. Full-Process Customization and Multi-Functional Adaptability
To meet the personalized needs of different industries and
products, this series of products has built a full-process
customization system covering 7 mainstream die casting processes:
For small zinc alloy parts (such as consumer hardware accessories),
the hot-chamber die casting process is adopted, which has the
advantage that the molten metal can directly enter the injection
chamber from the crucible, resulting in high production efficiency
and suitability for mass production; For large aluminum alloy parts
(such as automotive body components), the cold-chamber die casting
process is used, which can accurately control the temperature and
composition of the molten metal through an independent metal
melting furnace and injection system, ensuring the quality
stability of large castings; For components requiring high strength
(such as high-speed rail braking system components), the
high-vacuum die casting process is adopted to further improve the
casting density; In addition, it also includes semi-solid die
casting, squeeze die casting, differential pressure die casting and
other processes. The optimal process plan can be flexibly selected
according to the specific requirements of customers for casting
performance, material and size.
In the surface treatment link, the product also provides a variety
of customization options to adapt to the functional needs of
different scenarios: If corrosion resistance needs to be improved,
anodizing (for aluminum alloys) or chemical conversion coating (for
magnesium alloys) can be adopted. After treatment, the castings can
achieve no rust for more than 500 hours in the neutral salt spray
test; If the appearance texture and wear resistance need to be
enhanced, the powder coating process is available, with a uniform
coating thickness (50~80μm) and customizable colors according to
customer needs; If electromagnetic shielding is required for
electronic equipment, electroplating processes (such as nickel
plating, copper plating) can be used, with a shielding
effectiveness of more than 30dB; For components requiring heat
conduction (such as heat sinks), a special surface polishing
process can be applied to control the surface roughness below
Ra0.8μm, increasing heat conduction efficiency by 15%. At the same
time, all surface treatment processes comply with international
environmental standards (such as RoHS, REACH), and some processes
(such as anodizing) can meet the EN 45545 high-speed rail fire
protection standard, ensuring the safe use of products in special
scenarios.
3. Cross-Field Application Scenarios
- Automotive Industry: As a core component for the lightweight of new energy vehicles,
this series of die castings is mainly used in integrated body
structural parts (such as front floor, rear floor, battery pack
upper cover) and new energy vehicle battery casings. Taking the
application case of a new energy vehicle manufacturer as an
example, after adopting this series of integrated body structural
parts, the overall weight of the vehicle body is reduced by 40kg,
which is equivalent to increasing the cruising range per 100
kilometers by more than 10%; At the same time, due to the reduction
of a large number of welding processes, the production efficiency
of the body production line is increased by 40%, and the
manufacturing cost per vehicle is reduced by 800 yuan. In addition,
the battery casing adopts aluminum alloy material and high-vacuum
die casting process, which not only has a light weight but also has
excellent sealing performance (waterproof grade up to IP67) and
impact resistance, effectively protecting the safety of the battery
pack and meeting the strict requirements for battery safety of new
energy vehicles.
- High-Speed Rail Equipment: In the field of high-speed rail, this series of die castings is
mainly used in two key parts: bogie gearboxes and braking system
components. The bogie gearbox is the core of the high-speed rail
transmission system and needs to withstand high-frequency
vibrations and large torques during high-speed operation. Through
high-vacuum die casting + insert die casting technology, this
series of products enables the fatigue life of the gearbox housing
to reach more than 1 million times, fully meeting the "1 million
kilometers of trouble-free" operation standard of high-speed rail;
The braking system components (such as brake calipers) require high
strength and high-temperature resistance. This series of products
uses special aluminum alloy materials (such as AlSi10Mg), which can
maintain more than 80% of the room-temperature strength at 300℃,
ensuring the reliability of the braking system during emergency
braking. At present, this series of products has been applied to
EMUs on many domestic high-speed rail lines, with good operation
results.
- Electronic Communications: With the popularization of 5G technology, the demand for heat
dissipation and miniaturization of 5G base stations and terminal
equipment is becoming increasingly urgent. The application of this
series of die castings in this field mainly focuses on 5G base
station heat sinks and mobile phone middle frames. The power
consumption of 5G base station chips is much higher than that of 4G
chips, resulting in a significant increase in heat dissipation
demand. This series of heat sinks adopts thin-wall molding
technology (minimum wall thickness of 0.8mm) and a dense heat
dissipation fin design, increasing the heat dissipation area by 30%
compared with traditional heat sinks, and can control the chip
temperature below 65℃ to ensure the stable operation of the base
station; The mobile phone middle frame adopts an integrated die
casting process, integrating the middle frame with the antenna
bracket and camera bracket into one. This not only reduces the
thickness of the mobile phone by 0.5mm but also improves the
anti-drop strength of the phone body. At present, it has provided
customized solutions for many domestic mobile phone brands.
- Aerospace: The aerospace field has extremely strict requirements for
materials, which need to be both lightweight and have extremely
high strength and reliability. The core applications of this series
of die castings in this field are UAV housings and satellite
brackets. UAVs (especially military UAVs and logistics UAVs) have
high requirements for endurance and load capacity. The UAV housings
of this series use magnesium alloy materials, which are 30% lighter
than aluminum alloy housings, extending the UAV's endurance time by
20%; Satellite brackets need to maintain structural stability in
extreme space environments (high and low temperatures, vacuum).
Through precision casting and strict quality inspection (such as
X-ray flaw detection, ultrasonic testing), this series of products
ensures that the brackets have no internal defects, and the
dimensional accuracy is controlled within ±0.03mm, which can meet
the long-term reliability requirements of satellites in orbit.
- Consumer Goods Field: In the consumer goods field, this series of die castings is
mainly used in wearable device housings (such as smart watches,
smart bracelets) and sanitary hardware (such as faucet valve
bodies, shower brackets). Wearable device housings need to balance
lightweight, portability and wear resistance. This series of
products uses aluminum alloy materials and anodizing surface
treatment, which is lightweight (the weight of a single smart watch
housing is only 5g) and has a surface hardness of up to HV300 or
more, with excellent scratch resistance; Sanitary hardware needs to
have good corrosion resistance and water resistance. This series of
products uses electroplating processes (such as chrome plating,
titanium plating), which can maintain no rust for a long time in
acidic and alkaline water environments, and the surface is smooth
and easy to clean, improving the user experience. At present, this
series of consumer goods die castings has established cooperation
with many well-known home brands and wearable device manufacturers.
4. Quality Assurance and Technological Innovation
1. Full-Process Quality Control System
To ensure the quality stability of each batch of products, this
series of die castings has established a full-process quality
control system from "raw material entry" to "finished product
delivery". In the raw material link, all aluminum alloy and
magnesium alloy raw materials are sourced from well-known domestic
suppliers (such as CHINALCO, Yunhai Metal), and undergo strict
composition testing (using direct-reading spectrometers) and
mechanical property testing (such as tensile testing, hardness
testing) to ensure that the raw materials meet relevant standards;
In the mold design link, MAGMA casting simulation software is used
to conduct simulation analysis of the die casting process, predict
potential defects (such as air holes, shrinkage holes, cracks) in
advance, and optimize the mold structure (such as gate position,
overflow groove design). Through simulation optimization, the
number of test molds can be reduced by more than 30%, shortening
the mold development cycle; In the production process, an AI
intelligent monitoring system is adopted to collect key parameters
of the die casting machine in real time, such as injection speed,
injection force, mold temperature, and molten metal temperature
(with a sampling frequency of 100 times per second). Once abnormal
parameters are detected, the system will immediately alarm and stop
production to avoid the production of unqualified products; In the
finished product inspection link, in addition to conventional
dimensional inspection (using coordinate measuring machines) and
appearance inspection (using visual inspection equipment),
non-destructive testing (such as X-ray flaw detection, ultrasonic
testing) and mechanical property sampling inspection (such as
fatigue testing, impact testing) are also conducted on key
components to ensure that each product meets customer requirements.
2. Green Production Concept
Driven by the "dual carbon" goal, this series of products attaches
great importance to green production and has adopted a series of
environmental protection measures in production processes, waste
treatment, energy consumption and other links. In terms of waste
treatment, the scrap materials (such as leftover materials,
unqualified products) generated during the die casting production
process are classified, cleaned and smelted through professional
recycling equipment, and remade into alloy ingots for production
again. The waste recycling rate can reach more than 95%, which not
only reduces resource waste but also lowers the cost of raw
material procurement; In terms of energy consumption, a new
generation of energy-saving cold-chamber die casting machines is
adopted, whose motors and heating systems are all designed for
energy conservation. Compared with traditional die casting
machines, the energy consumption is reduced by 30%, and a large
amount of carbon emissions can be reduced every year; In terms of
environmental governance, the waste gas (such as die casting oil
fume) generated during production is collected through a gas
collection hood, treated by activated carbon adsorption + catalytic
combustion, and then discharged up to the standard; The waste water
(such as cleaning waste water) undergoes treatment processes such
as precipitation, filtration and neutralization, and is recycled or
discharged up to the standard, fully complying with national
environmental protection standards and realizing "win-win between
production and environmental protection".
3. Continuous Technological Innovation
To maintain the technological competitiveness of products, the
R&D team always focuses on cutting-edge technologies in the die
casting field and continuously promotes the performance iteration
of products. At present, it focuses on three major technical
directions: First, multi-material composite die casting technology,
which combines carbon fiber reinforced composite materials, 3D
printed metal inserts with traditional die castings. For example,
3D printed titanium alloy reinforcing ribs are embedded in aluminum
alloy die castings, which increases the strength of the component
by more than 50% without changing the weight. This technology has
been put into small-batch trial use in the aerospace field; Second,
the application of high-performance materials. In addition to
traditional aluminum alloys and magnesium alloys, titanium alloy
die casting technology is also under development—titanium alloy has
excellent high-temperature resistance and corrosion resistance, but
die casting is extremely difficult. The R&D team has
successfully trial-produced small titanium alloy die castings by
optimizing die casting process parameters and mold materials, which
is expected to be applied to aero-engine components in the future;
Third, intelligent manufacturing technology. Digital twin
technology is introduced to build a digital model of the entire die
casting production process, realizing virtual simulation, real-time
monitoring and intelligent optimization of the production process,
and further improving production efficiency and product quality
stability. At the same time, the R&D team has also established
industry-university-research cooperation with many domestic
universities (such as Tsinghua University, Harbin Institute of
Technology) to jointly tackle technical problems in the die casting
field and ensure that product technology is always at the leading
level in the industry.
5. Services and Support
To provide customers with a better cooperation experience, this
series of products has built a "full-chain, customized, and
efficient" service system, covering all links from pre-sales
technical communication to after-sales support. In the
pre-cooperation stage, the professional technical team will deeply
understand the customer's product needs (such as application
scenarios, performance requirements, size specifications) and
provide one-on-one material selection suggestions and process plan
design. For example, in response to a customer's demand for new
energy vehicle battery casings, the technical team recommends the
use of aluminum alloy 380 material + high-vacuum die casting
process by analyzing its structural characteristics and service
environment, and provides a detailed mold design plan and cost
estimation; In the mold development stage, the progress of the mold
(such as design completion, test mold time) will be regularly fed
back to the customer, and the customer will be invited to
participate in
