Why does the automotive industry prefer low-pressure die casting for producing lightweight components?

1. How to break through the bottleneck of lightweight material forming in low-pressure die casting?
High integrity forming of thin-walled complex structures
Low pressure die casting uses a slow filling pressure of 0.02-0.08MPa (compared to 30-150MPa in high-pressure die casting) to significantly reduce turbulence in the molten metal and avoid the entrapment of gas and oxide inclusions. This feature is particularly suitable for producing lightweight components with a wall thickness of ≤ 2mm (such as car door inner panels, motor housings), and can achieve high-precision mesh reinforcement ribs, embedded bolts and other complex structures, avoiding the "structural simplification compromise" of traditional casting.

Improve material utilization and mechanical properties
The lightweighting of automobiles requires a balance between strength and weight reduction, and the directional solidification technology of low-pressure die casting can optimize grain arrangement, enabling the tensile strength of aluminum alloys to reach 240-320MPa (close to forging level), while controlling the waste rate within 5% (sand casting waste rate is about 15%).

2. How does low-pressure die casting respond to the demand for cost reduction and efficiency improvement in the automotive industry?
Full lifecycle cost advantage
Although the initial investment of low-pressure die-casting molds is relatively high (about 20% more expensive than high-pressure die-casting molds), their process stability can reduce subsequent machining, welding, and assembly costs.

Environmental compliance drives process transformation
The EU's REACH regulation and China's "dual carbon" targets are forcing car companies to reduce energy consumption and emissions. The energy consumption of low-pressure die casting is only 40% -60% of that of high-pressure die casting, and more than 98% of the casting residue can be recycled, which meets the ESG (environmental, social, and corporate governance) transformation needs of the automotive industry.

3. How can low-pressure die casting empower the revolution of new energy vehicles?
Dealing with the strict requirements of the three electrical systems
Electric vehicles have extremely high sealing requirements for thermal management components such as motor water cooling sleeves and charging interface housings. The slow filling of low-pressure die casting can eliminate micro pores, making the airtightness of the casting reach IP67 standard, with a leakage rate of<0.1cc/min (typical values for high-pressure die casting are 0.5-1cc/min).

Adapt to the trend of multi material hybrid vehicle body
The steel aluminum hybrid vehicle body needs to avoid contact corrosion between dissimilar metals, while low-pressure die cast aluminum alloy components can generate a 10-25 μ m ceramic layer through surface micro arc oxidation, allowing the salt spray test corrosion resistance time to exceed 1000 hours, perfectly adapting to the connection requirements of steel frames.