Product description:
1. Product Definition: High-Pressure Molded Metal Precision
Components
Die-cast parts are metal precision components formed through the
high-pressure die casting process. By means of a die-casting
machine, molten alloys such as aluminum, zinc, and copper are
injected at high speed into the cavity of a precision mold, and
customized components are obtained after solidification and molding
under pressure. Their forms cover a full size range from micro
electronic accessories to large-scale car body structures.
According to the material, they can be subdivided into categories
such as aluminum alloy die-cast parts and zinc alloy die-cast
parts. Relying on the combination of metal fluidity and
high-pressure molding, they realize the integrated manufacturing of
complex structures.
2. Core Performance: Five Advantages Reshaping Manufacturing Value
- Efficient Molding and Cost Optimization
The die-casting process enables one-time molding of complex
structures, with the mold life reaching tens of thousands to
hundreds of thousands of pieces. Compared with traditional
processing, it reduces the amount of secondary machining by more
than 70%. Taking automotive structural parts as an example, the
integrated die-casting technology can integrate more than 70
scattered components into one piece, increasing production
efficiency by more than 5 times. At the same time, the metal
utilization rate exceeds 95%, significantly reducing material
waste.
- High Precision and Structural Stability
The product dimensional accuracy can reach grade 4-7, and the
surface finish can reach grade 5-8. The minimum wall thickness can
be 0.3mm (for zinc alloy) and 0.5mm (for aluminum alloy), with the
hole position tolerance controlled within ±0.02mm. Benefiting from
high-pressure solidification molding, the internal structure of the
component is dense (porosity < 1%), which is 30% stronger than
injection-molded parts. Moreover, there are no welding defects,
resulting in better overall rigidity.
- Lightweight and Multi-Performance Adaptability
Aluminum alloy die-cast parts are 30%-50% lighter than traditional
steel parts, and magnesium alloy components can achieve extreme
lightweight while maintaining excellent thermal conductivity (the
thermal conductivity of aluminum alloy can reach 200W/(m·K)) and
fatigue resistance. Through process optimization such as vacuum die
casting, the fatigue life of components can be increased by 3-5
times, meeting the requirements of high-intensity working
conditions.
- Flexible Surface and Assembly Adaptability
It supports a full range of surface treatments such as anodizing,
spraying, and electroplating, and can achieve smooth or textured
effects with only simple pre-treatment. The components can be
pre-designed with assembly structures such as screw holes and
inserts, and even fasteners can be directly embedded in the mold
for simultaneous die-casting, greatly simplifying the subsequent
assembly process.
- Material and Process Innovation Upgrade
It is compatible with special materials such as high-silicon
aluminum alloy and heat-resistant magnesium alloy. Combined with
the 12,000-ton super-large die-casting machine technology, it can
form integrated heavy parts such as new energy vehicle chassis. By
optimizing the mold design through MAGMA simulation, the mold trial
cycle is shortened by more than 40%.
3. Full-Scenario Application: Empowering Manufacturing Upgrade in
Multiple Industries
Among the application fields of die-cast parts, the automotive industry accounts for 60% of the market share and is a core application
scenario. Typical products in this field include the integrated
die-cast rear floor and battery pack shell of Tesla Model Y. Such
die-cast parts can integrate 79 originally scattered components
into a single component, not only achieving a 30% weight reduction
effect but also meeting the IP67 sealing standard, providing key
support for the structural optimization and performance improvement
of new energy vehicles.
In the consumer electronics field, die-cast parts also play an important role. For example, the
recycled aluminum middle frame of iPhone SE and the 5G base station
radiator are both manufactured using the die-casting process. With
the 0.5mm thin-wall molding technology, these products not only
meet the lightweight requirements of consumer electronic products
but also have good electromagnetic shielding performance and
efficient heat conduction capacity, ensuring the stable operation
of equipment.
The rail transit industry has more stringent requirements for the performance of components.
The application products of die-cast parts in this field include
high-speed rail bogie gearboxes and braking system components. Such
die-cast parts have excellent high-frequency vibration resistance,
and their fatigue life is increased by 5 times after process
optimization. They can adapt to the complex and high-intensity
operating environment of rail transit and provide reliable
guarantee for driving safety.
In the high-end manufacturing field, die-cast parts also show unique advantages. For instance, drone
bodies and robot joint modules are produced using the die-casting
process. Such components achieve a perfect balance between
lightweight and rigidity, which can not only reduce the flight load
of drones and improve battery life but also ensure the flexible
operation and structural stability of robot joints. At the same
time, they support the rapid iterative development of products,
helping the innovation and development of the high-end
manufacturing industry.
4. Quality Assurance: Full-Process Defect Control System
Relying on an intelligent production system, common defects in the
industry are avoided from the source: by real-time monitoring of
die-casting temperature (aluminum alloy mold temperature ≥ 180℃)
and injection speed, problems such as flow marks and cold shuts are
prevented; environmentally friendly coatings with gas evolution ≤
5ml/g are used, and a full-range exhaust system is matched to
eliminate air hole defects; the alloy composition is strictly
controlled (the iron content of aluminum alloy is 0.6%-0.8%) to
prevent mold sticking and scratches. Each batch of products
undergoes 3D scanning dimensional inspection and non-destructive
testing to ensure compliance with the ISO/TS 16949 automotive
industry standard and the EN 45545 rail transit fire protection
specification.
Versatile Die Casting Spare Parts Small Precision Casting Aluminum Parts
