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The following article was published in our article directory on November 4, 2011.
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Automobile Die Casting Aluminum Parts

Article Category: Automotive

Author Name: Bob Thomas

Strength and durability - These are the most important requirements for automobile parts. Nowadays, the industry has a strong demand for die castings used for automobile parts. Die casting is a metal working process that performs efficiently on large-scale productions. If we will compare it with other processes like extrusions, die castings produce automobile parts with higher yield strength (breaking point). It is used to produce both mechanical and fixed parts of automobiles

The details and the advantages of die cast parts, one must know the simple processes behind it. First, the metal is melted in a furnace separate from the die fixture. Then, it will be injected into the dies. A pair of dies forms the mold cavity, which contains the intended shape of the part. This is known as cold-chamber processing, which is common in producing die castings used for motor vehicle parts. As the metal hardens, the dies are intensely compressed. The pressure results in very strong castings.

Die Casting molds and tools for automobile die casting are very expensive, reaching hundred thousands of dollars. The large capital makes the process suitable only for large-scale manufacturing lines. However, it is a wise investment because it minimizes human intervention for die castings used for motor vehicle parts. Die-casted products are precise in depth, size and shape. This is great for fixtures, frames, sprockets and engine blocks of automobiles. The process produces little or no scrap and deformities. Therefore, there is no need for post-machinists to perform trimming or sanding. If there are metal scraps, they can easily be recycled.

Most car parts companies are now using die casting. It is a metal-working procedure which is intended for large scale productions. Car die cast parts are known for ease in production and performance against multi-directional stresses. These parts are used as stationary parts like the vehicle frame and engine fixtures. They are also intended for mechanical parts like gears, engines and chains.

Die Casting and its variants always compact molten or semi-molten metals. Hence, pressure and temperature are always crucial factors. As for automobile die cast parts, they are usually created through cold chamber die casting. The type of casting depends on the type of metal. Majority of metal products in the automotive industry use aluminum and magnesium. Cold chamber method is the one appropriate for such high-melting point metals.

The process of making die castings, like car parts, is simple. The metal is melted in a separate furnace. As it is cooling down, it will be transported to the dies, which contain the target shape. Depending on the strength specifications and type of metal, pressures between 10 to 175 mPa will be continued until the metal solidifies. This can produce a wide range of shapes from the simple to the intricate: rods, bars, billets, planes and fixtures. They require little or no post machining because die casting results in precise shapes and thickness.

Motor vehicle die cast parts include engine blocks and some gears, which are mostly made of aluminum and magnesium casts. The joining together of these two metals is very tough, even when subjected to repeated load and high temperatures.

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