Die Casting Process: A Trusted Aluminium Auto Parts Manufacturing Process

The modern automotive industry is heavily dependent on die casting process. Die casting is a popular metal casting procedure where molten metal is either forced or poured into steel molds. These molds are also known as dies or tools. They are created utilizing steel and they are particularly designed for all projects. Thus, every element is created with repeatability and preciseness. The commonly used materials utilized in die casting are zinc, magnesium, and aluminum. The automotive industry mostly uses aluminium die cast wheels and parts. Die casting provides a high dimensional accuracy. It also allows the mass production of complexly shaped auto parts.

Types of die casting

Three types of die casting processes include:

• Low-pressure die casting
• High-pressure die casting
• Gravity die casting

At the manufacturing facilities of Rockman Industries, all three die cast manufacturing processes are used.

A brief overview of low-pressure die casting

In low-pressure die casting (LPDC), low pressure between 14 PSI to 29 PSI is used for filling molds with molten metals like aluminum. In LPDC, the holding furnace remains below the cast and you can force liquid metal upwards using a rider tube. You need to apply this pressure consistently, at times, in increasing increments to fill the mold and hold the metal right in place.

Benefits of LPDC in the automotive industry

The automotive industry relies on LPDC for creating superior-grade and sturdy casts. Earlier, its usage was confined to the automotive market only but now it is utilized for the casting of many automotive parts including cylinder heads and wheels as they need good integrity.

What is meant by high-pressure die casting?

HPDC or high-pressure die casting is a procedure where molten metal is compelled into a safely locked metal die cavities under high pressure between 1500 PSI to 25000 PSI where it solidifies after some time. After the metal gets solidified, the die gets unlocked and the casting is ejected.

Advantages of HPDC for bike and car manufacturers

Bike and car manufacturers use HPDC from a reliable company like Rockman Industries as it allows the usage of aluminium alloys and they are both strong and lightweight. It results in enhanced fuel efficiency in different vehicles. The process of HPDC creates minute geometries with a tight tolerance. It simplifies the process of producing parts that have complicated designs. As HPDC has fast cycle times, it seems the best option when automotive parts are produced in large quantities.

An overview of gravity die casting (GDC)

Gravity Die Casting is the most traditional die casting process. In this process, a vessel or ladle is used to pour molten metal into the mold. The mold cavity becomes filled with no force and you can control the filling when you tilt the die. Again, you can also incorporate cavities and undercut into a component form with the usage of sand cores.

Why do car and bike parts manufacturers use gravity die casting?

Bike and car manufacturers like Rockman Industries use gravity die casting as it can create high-quality, lightweight, and complex metal elements with superb surface finish and dimensional accuracy. Thus, it seems to be perfect for creating different automotive parts including suspension parts, engine components, body panels, and brake calipers where precision and weight reduction turn into critical factors.

Conclusion

Die casting has remarkable benefits over other automotive parts manufacturing processes. The die casting process offers multiple manufacturing conveniences that help in precision finishing and reduce manufacturing expenses significantly. Rockman Industries is a pioneering name in this domain, offering customizable alloy wheels and automotive parts to the top two-wheeler and four-wheeler brands.