Current Status and Development Trends of Aluminum Alloy Casting Parts for Automobiles
Release time:
2025-02-09
Especially in the field of new energy vehicles, the penetration rate of aluminum alloy castings has exceeded 50%, widely used in battery pack housings, motor housings, and body structural parts.
Development Trends
1. Continuous upgrading of lightweighting needs: The pressure to reduce emissions from fuel vehicles is driving the replacement of traditional steel, forgings, and cast iron parts with aluminum alloys. Electric vehicle range anxiety drives lightweighting (a 10% weight reduction can improve range by 6%-8%), and the amount of aluminum per vehicle may reach 200kg by 2030 (currently about 150kg).
2. The explosion of integrated die-casting technology: The technological advantages lie in reducing welding steps and improving production efficiency (Model Y rear underbody manufacturing time reduced from 1-2 hours to 3-5 minutes); material innovation lies in high-strength, heat-treatment-free aluminum alloys (such as Alcoa C611, LIZHONG LDHM-02) breaking through the limitations of traditional materials; equipment upgrades mainly lie in the rapid development of large-tonnage die-casting machines. Reports indicate that 16000T models have been put into use, supporting the production of larger parts; material and process collaborative innovation lies in the development of high-strength aluminum alloys with tensile strength exceeding 300 MPa, extending to safety-critical components such as A/B pillars. Vacuum die casting can reduce porosity defects. Integrated die-casting technology is expanding from the rear underbody to the front compartment and battery pack housings, developing towards larger integrated components.
3. 3D printed sand molds: 3D printed sand mold technology has shown significant advantages in the trial production of complex structural parts, shortening the development cycle by more than 50%. It enables rapid prototyping of complex structures, shortening the development cycle.
4. The surging demand for new energy "three-electric" systems: Aluminum alloy accounts for over 80% of battery pack housings, and die-casting technology is gradually replacing stamping and welding (weight reduction of 15%+); the water-cooled design of motor housings drives the demand for thin-walled, high-thermal-conductivity aluminum alloys; the 800V high-voltage platform requires aluminum alloy solutions with higher electromagnetic shielding performance.
5. Circular economy and sustainable development: Recycled aluminum applications: Automakers require a recycled aluminum ratio of over 30% for parts (such as BMW's BMW i series). Closed-loop recycling: Tesla promotes the in-plant reuse of die-casting waste, reducing carbon emissions.
6. Digital development: AI simulation optimizes mold design, reducing trial-and-error costs. Applications of digital process control and AI intelligent scenarios, etc.
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