Die Casting Automotive Parts

Inox Cast Die Casting Automotive Parts

Inox Cast is a world-leading manufacturer and supplier of a wide range of die casting automotive parts. As a professional manufacturer, we have a full capability in manufacturing the best quality die casting automotive parts.

Inox Cast offers to die casting automotive parts available in OEM services. We are a manufacturer that is accustomed to manufacturing and providing the best die casting automotive part solution in time. We are consistently improving our product’s quality to meet industry tolerances and standards.

We manufacture die casting automotive parts using high-quality materials. We used magnesium, aluminum, zinc, and more. These also undergone heat treatment to ensure their durability and long-life use.

Inox Cast has unrivaled experience in developing, designing, and producing die-cast automotive parts. Inox Cast dies cast automotive parts are perfect for protecting electronic equipment and telematics.

It also functions to intricate lock barrels. Our die-cast automotive parts are lightweight for improving the vehicles’ fuel economy. We also have to die-cast automotive parts that serve as connectors for an autonomous vehicle.

Advantages of Inox Die Casting to Automotive Industries

• Flexibility and versatile design for complex parts
• A broad range of surface treatments
• Components are made from lightweight magnesium and aluminum
• Can create components in all shape and sizes
• Precisely cast
• Fully recyclable

Inox Cast exports die casting automotive parts to different countries around the world. Our products are widely known in the international market because of their high-quality, reliable performance, and competitive price.

Request a quote for your next die casting automotive parts order!

Die Casting Automotive Parts: The Ultimate FAQ Guide

Die casting automotive parts is a common process in today’s industrial set up.

A reason this guide explore all the fundamental aspects about die casting automotive parts.

So, before starting your next die casting automotive parts project, read this guide.

Which Automotive Parts Can You Die Cast?

The die casting technique is very famous for fabricating metal components for house hold and business structure and even automotive parts.

Die casting is metal processing technique whereby liquefied metal is molded into a die casting mold by utilization of pressure.

die casting automotive parts

Vehicles have the most numeric die cast parts as it mostly include some addition of die cast parts examples are listed below.

Some of the examples of die casting automotive parts include;

Engine Parts

The engine cylinder heads and the gas engine parts are very inclusive in the die cast aluminum components.

Stator

They’re created by die casting because of diversity in size, die casting is greater technique of fabricating this automotive part type

Brackets

Brackets are utilized for electric motors and stepper motors per your preference designs, brackets are an example of an automotive components.

Electronic Covers

The covers for gear box, motor, shades pole, and stepping motor are some of the examples of the electric covers components.

Transmission housing, valve covers, wheels, cylinders, engine block, wheel spacer impellers, carburetors, and fan clutch, housing alternator, auto-fork, heat sinks.

Sunroof components, seatbelts, chassis parts, air-conditioning systems, power steering systems, fuel intake parts, car inside parts.

Parts

Parts of the fittings handles, dampers, switches and blinders are from the zinc alloys housing of wiper motors, seat belts.

Which Materials Are Best For Die Casting Automotive Parts?

Zinc Alloys

Zinc alloys is actually utilized alloys for the die casting because of its lower price of the raw material.

The zinc alloy is indeed one of the powerful and stable metals plus it has amazing electrical and thermal conductivity.

zinc alloy

The rust Impediment feature also precisely enables the parts to precisely last over a long period of time or be durable.

It is one of the most cast metals because of its decreased melting point, it is utilized mostly inside mechanical components.

The more significant autonomous driving becomes the more significant the electrical influences will automatically become.

Examples is a housing of wipers motors which ensures that the parts that are important to transmission does not correlate.

Zinc is also a useful and a material-efficient matter which is actually re-used precisely and taken back to the matter cycle.

It actually meets the difficult and strict safety requirements that are precisely used on the interior of the car or vehicle.

The reason why belt rewinds power or strength and functionality in dangerous times where life and death are at stake.

Gives the best quality surface of products, it makes slender tolerances and the exterior of items created by zinc is smooth.

Its constant remain in the weight to the matter power which will make it precisely possible to decrease the vehicle weight.

Aluminum

Aluminum is one of the more adaptable metals it’s utilized for a number of products and industries, has low melting point.

The major reason for the utilization of aluminum metal is that it withstands most elevated functioning temperatures it’s strong and durable.

aluminum

Features

It’s durable and strong thus withstanding and functioning properly in harsh weather conditions or temperatures making obvious reason to utilize aluminum.

Aluminum is feather weight, that’s why industries in automotive and powers parts fabricate their parts with aluminum due to better vehicle handling

It is one of most elevated strength to weight ratios metal enabling it to actually be one of the longest durable alloys.

Aluminum alloy is a versatile metal naturally its formability and its corrosion resistance enhances it to work easily with and shape.

Ease to operate with the quality performance is shown through diverse manufacturing stages like drawing, brake hardening annealing and extrusion.

Decrease of car weight and increase fuel economy due to its light in weight especially in the electric vehicles or cars.

Aluminum can be molded with a scale of elements to bring out characteristics like power, conductivity of elements resistance to corrosion.

Parts

Wheels, engine radiators, bumpers, suspension parts, engine cylinder blocks , transmission bodies and body parts holds, the doors and frame.

Heat insulators, license plates, motor bike handles, shock absorbers,

Brake components, con-rods, pistons, piping, compressor rotors , lashing rails, bonnets, seat frames.

Tank, fuel delivery pipes, propellers shafts, truck bed gates, bumper reinforcement, seat hinges, steering components, seat sliders , keys, AT valves.

Magnesium

This metal alloys is similar in features like aluminum and zinc its strong, firm matter and is utilized for electronic products.

magnesium

Features

It is a feather weight material and has a good strength to weight ratio and is also rust impediment metal too.

Unlike the aluminum metal, magnesium is actually smoother and less firm or stable and prefer to bend very easily on stress.

Its actually too pricey compared to aluminum due to its high melting  point unlike zinc, this leads to elevated casting costs.

Parts

Gear box, front end, IP beams, steering column and drivers air bag  housings, fuel tank covers, seat frames and  oil pumps.

The  magnesium alloys are good when it comes to the properties during casting  and the reduced porosity shrinkages or a micro-cracks.

Copper

Consists of elevated hardness, elevated corrosion resistance , elevated mechanical characteristics, excellent wear resistance it also consists of excellent stability in dimensions.

copper

Parts

Wire harness, starter motor, alternator, radiation, brake tubes, electrical driving controls, gear box, innovative heat exchangers.

Features

Elevated  conductivity in electricity

Elevated conductivity in electricity wire harnesses are created with copper that moves current from battery to diverse devices on the car.

Motor equipment in the  car that that are wound with copper wire are the electrical motors making copper good in conductivity.

Elevated Heat Conductivity

This feature makes copper efficient material for car radiator which function is cooling engines by moving heat from coolant to air.

Excellent rust resistance

The tubing brake needs excellent rust resistance metal due to weather conditions and copper is one metal to do the job.

Great bearing features or  characteristics

Copper alloy that gets in contact with parts of moving engine will give an exterior that will not stick or corrode.

And then bearing in mind that it is also powerful or strong enough to give support thus acting as a bearing.

What Are The Benefits of Die Casting Automotive Parts?

There is usually freedom in more varieties or diverse designs or creations and adjustability to design complicated components desired by you.

Some metals like the aluminum and magnesium will precisely produce parts that are light feathered in weight thus help reducing car weight.

An accurate cast and the slender-walled housings will give you protection for an ever-elevating notation of the electronic sensors thus advantageous.

With use of die casting there is skillfulness or potential to position or locate electronic parts and thermal-sink within net-form creation.

It will actually provide important protection for the telemetric, which co-ordinates telecommunications, navigation, and the entertainment systems inside the car system.

Provides housing connectors for electrical system and electronics inside car that’s fabricated in forms and sizes with use of zinc, aluminum, magnesium.

There is complete reuse die casting that assist to accomplish tight product reuse requirements, it also gives diverse specifications and finishes.

The parts are usually durable and compactly stable and there is usually elevated rate of fabrication with little machinery or no.

The zinc castings give great rust resistance and the holes could be curved and formed to actually give accurate hole diameter.

Gives soft exteriors compared to most kind of casting like the sand and gives integral fastening elements thus reducing production price.

Its advantageous actually when there is need for a large fabrication, it enables thousands of similar castings within the instructed tolerances.

In metals like zinc there’s usually a benefit of adjustability thus assist in fabricating complicated parts in shape with slender walls.

With aluminum metals there is safety and reliability. It’s attainable to create devices being heat resistant, friction and impact-proof to shield.

The parts are manufactured which are precisely slender walled and light but be very powerful or strong at the same time.

Are There Limitations Of Die Casting Automation Parts?

They easily cause porosity in die castings

As liquefied metal occupies the mould hole at elevated velocity, during casting as well as mould matter having no gas penetrability.

This causes gas hole and because of this, the casting can’t be enhanced by thermal treatment and utilized at elevated temperature.

At exact time, apparatus space of components shouldn’t be too big, because firm-layer on exterior of die casting will be peeled.

Gives low die life during the casting of elevated melting point alloy-

Copper alloys have elevated melting point thus have elevated needs for heat distort resistance and heat exhaust power of die casting matters.

Enormous money investment-

The casting equipment needed, the dies and related apparatus are very pricey especially on starting out unlike the other casting methods

Casting weight is restricted to be between 30grams and 10kg and the size of the casting must be smaller than 600mm.

It’s only limited to low melted metals and is also very costly when you want the smaller components compared to larger production.

The modifications to component design are time taking and very pricey, thus worth prototyping the part before consigning to die casting.

Which Techniques Do You Use In Die Casting Automotive Parts?

Multi-Slide Die Casting Automotive Parts-

The multi-slide die casting technique utilizes four vertical slides in the gadget allowing very complicated and precise castings to be fabricated.

Die cast gadget technique is utilized mostly for small zinc parts, however multi-slide die casting gadget is made capable for magnesium.

With this technology you actually have the free will to design more accurate and complicated components design of your own choice.

Multi-slide tool is buildup of die blocks sliders, crosshead, and cover plate, each die block contains holes and cores on surface.

Cavities on surface of die blocks actually united make full or entire hole and runner profile where liquefied metal is injected.

Multi Slide Die Casting Process

The multi-slide  die blocks are precisely connected into sliders, which fit accurately into a cross-head enabling continual opening and closing action.

Cover plate coursed on top of tool holding all parts together, each slides shift alone without other on opening and closing.

This shift gives tremendous adjustability, guaranteeing compartment integrity and averting destruction of gadget metal cools in seconds is removed with air-blast.

Multi-slide casting gadget cycles at velocity of 75cycles per minute its accomplished by utilizing pneumatic to control diverse components of equipment.

Mechanical on/off switch techniques, hydraulic thrusters supplement fragile locking force accessible with pneumatics enabling die casting gadget to be firmly during injection.

Benefits-

Congruous component quality,

Erase or decrease of secondary activity ,

Reduced gadget prices,

Perfection component to component persistently,

Fast die changeovers.

In-die degating and mechanical division of components from runners,

Flash-free castings,

Fast cycle velocity,

Price savings in matter,

Energy and work.

Hot Chamber Die Casting Automotive Parts-

Hot chamber process is also known as the gooseneck casting technique or hot die.

In this technique, the plunger and chamber of injection instrument is inserted in the liquefied metal bath of a metal furnace.

With the dies covered, the plunger pull out and opens chamber port to permit liquefied metal to stream inside chamber.

The plunger seals the port while pushing the liquefied metal into the die hole through the hot die and the hole.

After entering the die hole or die cavity the liquefied metal is then gripped under pressure until it cools in the die.

This method of casting is suitable in involving metals with decreased melting points like tin and zinc

Benefits

It gives a quick yield rate of up to 18000 shots per hour for the little parts

Fabricates components with decreased porosity.

Liquefies the metal inside the die casting gadget.

This method yields little wastage.

Extended die life due to the decreased melting point.

Limitations

Price-effective only for larger volume fabrication batch.

Elevated-melting point metals cannot be utilized.

Elevated pressure scale is needed.

Less metal fluid thus limited the yield complication.

Thermal treatment issues

Ejector marks and little amounts of flash at the die separating line may remain.

Cold Chamber Die Casting Automotive Parts.

In the cold chamber techniques liquefied metal is poured into shot sleeve before thrusting into the mould because sleeves not heated.

Because the metal melting pot is different it does not have a rust issue

The cold chamber method begins when the liquefied matter is exchanged into the shot chamber from the furnace through pouring hole.

Then a hydraulic plunger covers the cold chamber port and then exerts pressure on metal into the mould hole at pressure.

This technique is utilized for elevated point alloys of aluminum, magnesium, copper, including low melting point metals can also be cast.

Benefits

Higher-strength parts, denser metal casings, due to elevated pressure during injection, lower maintenance cost, it brings exceptional dimensional accuracy to the part.

Possible high speed production

Simple to carry out process

Limitations

Slow cycle time than hot chamber die casting

It might be due to transferring the metal from the furnace to the chamber

The level of oxidation under other contaminants remains high in the process

The quality of the final part is more prone to be affected due to pollutants

Vacuum Die Casting Automotive Parts

This method removes air through vacuum valves, this vacuum is the more efficient way to remove air from hole of mold.

Process

Before injections shots occurs, a vacuum is drawn in mold hold and shot sleeve then all gas is actually removed from mold.

Then vacuum is hold up-to time when the injection cycle is completed, this helps to decrease porosity in parts.

Importance of decrease in amount of air porosity, pore sizes in casting as led to improvement of thickness and tensile strength.

Benefits

Enable thermal treatment and welding

Mostly the die cast components are not good for thermal treatment, due to the air pores available in the die castings.

It will end up creating blisters on the surface because of the elevated temperatures, with vacuum die casting this problem is eliminated.

The yielded components with vacuum die casting will actually be able to be welded when necessary and allow also thermal treatment.

Limitation

Are supplements , they cant give a great die casting creation practice in the engineering of holes, runners, gates and also overflows.

Applications

Automobile, aerospace, military,  marine, contractions.

Squeeze Die Casting Automotive Parts

This is a process that uses hydraulic press to press the liquefied metal under pressure on the closed dies to solidify.

Pressure applied and immediate touch of liquefied metal with die surface gives a fast thermal exchange conditions that produces smooth surface.

The process

The technique actually begins with the liquefied metal or molten metal being poured into the bottom half of a pre-heated die.

The minute the metal begins cooling, the upper part of the die covers and begins giving pressure on the cooling process.

The range of pressure given is importantly less than that in forging and component of the great details can be made.

Coring is utilized in tandem with process to make cavity elevated pressure and close contact of liquefied metal-with die exterior leads to less-porosity.

Benefits

Gives a variety scale of shapes and parts compared to other fabricating techniques and less or no equipment is precisely needed.

Reduced levels of pores and great exterior texture that has fine micro-structures with elevated power parts and has no waste materials.

Limitations

The prices of complicated design is very high and there isn’t adjustability for different designs is specific for specified design parts.

The process always requires to be really precisely controlled, which will actually slow the cycle period and raises the process costs.

Because of increased price or elevated cost, it means that yield have to be increased so as to justify gadget investments.

Semi-solid Die Casting Automotive Parts.

There are a variety of different methods to create semi-solid castings.

semi solid die casting automotive part

Thixo-casting

Uses a pre-cast billet with non-Dendritic  micro-architecture that is usually produced by actively stirring the melt as bar is casting.

Thixo casting

Inducting heating usually utilized to re-heat billets to semi-solid temperature scale, die casting gadget is utilized to inject semi-solid matter in steel dies.

Benefits

It actually consists of ability to make extremely elevated quality parts because of product consistency that comes from utilizing pre-cast billet.

Limitations

It’s costly because of special billets that needs utilization although industries with in-house magneto-hydrodynamic keeps casting abilities reuses in-house returns.

Limited variety of alloys is utilized for industries that doesn’t have in-house magneto-hydrodynamic casting ability scrap cant be recycled directly.

Rheo-casting

This method is different from other as it develops the slurry from liquefied metal yielded in a normal die casting furnace.

Rheo casting

Benefits

Leads to decrease cost when it comes to feedstock, in the form of normal die casting alloys, and enables direct re-use.

Limitations

Has  process control problems like usually, when there is a surge of activity, very small matter is fabricated via rheocasting.

Thixo-molding

It is used for   magnesium alloys.

This utilizes a gadget same as injection molding, in one step process, room temperature magnesium alloys parts are put into the end of a pre-heated container.

Thixo mouldling

Benefits

Free porosity

Reduced shrinkage

Excellent mechanical performances

Pressure tightness, tight tolerances, thin walls

Heat treatable

Good surface finish.

Why Is Precision Die Casting Automotive Parts Important?

Lighter Component Weight

Made with aluminum because it works best with elevated detail molds utilized for type of qualified matter casting, it’s lightweight.

A lightweight car is gas economical and enables fabricator to decrease strength of engine to meet emissions standards without omitting the speed.

Because aluminum components are created with precise die casting they are very long lasting and no elevated repair are needed either.

Quick manufacturing Process

This method is usually of highly mechanical process, with the technicians authority,  the creation in-put and having little hands-on-input in fabrication.

Precise die casting is very fast, very effective especially in production of large volume of parts even those with entire variations.

Decreased Price For Fabrication

Gives elevated quality of machined product with an economical cost as it can be utilized for design models and volume fabrication.

Its adjustable and economical enough to be utilized for many purposes on the  automotive fabricating life cycle, decreasing need for subcontractors.

Elevated utilization of re-used matter

Because precision casting depends on aluminum and deforms metal title on casting, both complete components and any off-cast matter is recycled.

Decrease need for thermal treatment

This technique makes components that are ready to handle pressure of engine with no need for thermal treatment to enhance strength.

Preciseness of components fabricating from precision die casting

Precision die casting actually will gives out very slender walls, tight curves, complicated channels and the other varieties of creation on characteristics.

Can You Die Cast Thin Walled Automotive Parts?

Yes,

You can die cast thin walled automotive parts, it gives superior strength-weight other than the parts fabricated by other methods.

It’s also economical and designs unlimited number of varieties unique product shapes and sizes for industries.

Is OEM Die Casting Automotive Parts Business Profitable?

Yes,

Because of competitive pricing the parts are very cheap due to enormous production efficient process and supply chains.

They have full access to experts and automotive machines thus giving a standard quality of products.

Reduced capital/investment price and protect yourself against fluctuations in operational costs.

They form on product development marketing and sales.

Which Defects Are Common In Die Casting Automotive Parts?

Gas porosities

Deformation

Cracks

Blisters

Flow marks

Cold flow

Network cracks

Sinks

Short filling

Flashes

Inclusions

Inter-layers

Drag and soldering

How Do You Test Quality Of Die Cast Automotive Parts?

Destructive Examination

After every fabrication run, one will choose few prototype and deliver them for destructive testing, prototype is broken characteristic inspected closely.

The examiner checks for the signs of porosity, inclusion and shrinkage this gives a sense of overall quality of the manufacturing.

Non-destructive testing

This is carried out by the foundry laborers, clients and NDT technicians to confirm the inside and exterior soundness with no destructions.

Visual Inspection

This technique actually is the using of your own eyes to inspect and identify exterior deformations, crackles, porous and molding flaws.

Dimensional Inspection

This inspection is being done to ensure component meets the dimensional needs. It’s done manually by a measuring device utilizing probes.

Liquid Dye Penetrate Inspection

The tester cleans the casting, then adds a penetrate solution, its left for some time to find its way to invisible cracks.

Magnetic Particle Inspection

This is used to identify tiny crack and cavity on exterior of casting, utilized for casting made of the ferromagnetic metal.

Ultrasonic Testing

This test finds defects by utilizing elevated frequency acoustic energy transmitted into casting in a technology like ultrasounds.

What Are The Benefits Of Aluminum Die Casting Automotive Parts?

Automotive factor weight Promotion, energy-saving, environment friendly

The weight of the car is reduced by the use of aluminum die casting parts and this leads to fuel efficiency.

Aluminum alloy component are re-usable and thus save energy eventually.

Aluminum alloy has the property of corrosion resistance, which helps prolong the life of automobile.

The extensive application of cast aluminum auto parts help increase the stability and safety while driving.

Inox is here to help get all you get all die cast automotive parts, depending on your unique requirements and specifications – contact us now.