Product Specification
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| Payment Terms |
L/C,D/A,D/P,T/T,Western Union,MoneyGram |
Supply Ability |
1000000PCS/M |
| Delivery Time |
25 working days |
Packaging Details |
As the requirement of customer |
| Name |
Die Casting Parts |
Surface |
coating, electrophoresis, etc |
| Part Material |
Aluminum / Zinc / Magnesium Alloy Parts |
Mold Cavity |
Single cavity / Multi-cavity mold |
| Product Type |
Custom aluminium die casting parts |
Mould Hot Treatment |
Tempering,Quending,Nitriding |
| Manufacturing Lead Time |
15-20 Days |
Service |
custom |
| Surface Finishing |
Custom Surface Texture |
Standard |
ANSI |
| Brand Name |
Race |
Model Number |
Die Casting |
| Certification |
ISO14001 |
Place of Origin |
Guangdong, China |
| High Light |
Aluminum Die Casting Parts
，Zinc Alloy Die Casting Parts
，OEM Die Casting Parts
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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
Company Details
Bronze Gleitlager
,
Bronze Sleeve Bushings
and
Graphite Plugged Bushings
from Quality China Factory
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Business Type:
Manufacturer,Distributor/Wholesaler
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Total Annual:
7000000-8000000
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Employee Number:
100~150
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Ecer Certification：
Verified Supplier
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