Lightweight Aluminum Die Casting For New Energy Vehicle Parts

The growing market for electric vehicles (EVs) necessitates the development of sophisticated, lightweight, integrated, high-performance manufacturing technologies. Aluminum die casting is one such manufacturing technology whose characteristics (i.e. high adaptability for complex structures, lightweight, high production volume) are beneficial for manufacturing parts for new energy vehicles (NEVs). KT offers integrated manufacturing solutions from prototype to mass production including aluminum die casting, precision CNC machining, tooling, and surface finish to support the dynamic needs of the automotive industry.

Why New Energy Vehicle Parts Use Aluminum Die Casting

Parts of new energy vehicles (NEVs) must be lightweight, strong, and allow for heat dissipation, as well as be durable. For manufacturing of these parts, aluminum die casting is the suitable technology.

1. High Strength-to-Weight Performance

Parts manufactured through aluminum die casting allow for significant weight savings over traditional steel parts, while still allowing for component design.

In electric vehicles, every incremental mass reduction is beneficial as it may provide an improvement in energy efficiency and an increase in the driving range.

2. Complex Structural Integration

The high-pressure die casting process allows the manufacture of complex parts that can include multiple features such as:

•   Internal ribs to strengthen the part

•   Bosses for assembling parts

•   Cooling channels for heat removal

•   Reinforced sections to support loads

This design capability reduces part count and simplifies assemblies.

3. Thin-Wall Manufacturing Capability

With respect to modern aluminum die casting, the lower limit for wall thickness for castings is roughly 1.5 mm, although in some instances walls can be even thinner. The upper limit for wall thickness for thin wall die casting is about 5 mm. The precise limits for wall thickness for a given application can depend on a number of factors, including selection of the aluminum alloy, the design of the casting, as well as the overall dimensions of the part.

The ability to cast thin wall sections can help in the development of lightweight automotive designs that still meet performance requirements.

4. Constant High-Volume Production

After the necessary tooling for aluminum die casting has been completed, the production of automotive components through this manufacturing process can be done consistently in high volumes.

Aluminum die casting is capable of producing significant quantities of components with consistently high quality, thanks to the controlled parameters of the process.

KT's Comprehensive Manufacturing Strategy for New Energy Vehicle Parts

KT combines its die casting with its engineering, tooling, machining, and finishing capabilities to provide customers with a complete manufacturing solution.

The integrated approach shortens the customer's manufacturing value chain and ensures part consistency throughout its lifecycle.

1. From Tooling Development to Mass Production

Die Casting Tool Design And Optimization

Aluminum die casting tools must be designed for each specific application, taking into account the geometry of the part, the material, and the production requirements.

In the die tool design, the following factors must be analyzed:

•   Flow of the molten metal into the cavity

•   Cooling channel design

•   Location of the parting line

•   Ejection system

•   Desired durability of the tool

Involvement of engineers in the early stages of tool design helps reduce risks associated with the manufacturing and enhances the stability of the casting process.

2. Design for Manufacturability (DFM) Support

Prior to beginning production, KT provides DFM guidance to optimize the die casting design of New Energy Vehicle parts.

The following design aspects will generally be modified for optimization:

•   Consistent wall thickness

•   Correct draft angle

•   Low height ribs and bosses

•   Excess stock for machining

•   Production tolerances

Effective design improves the die-casting process and reduces the necessity for machining, thus creating a more efficient and less variable process.

3. Prototype and Low-Volume Production

KT performs prototype validation as a part of a new product's development cycle, providing:

•   CNC machined aluminum prototypes.

•   Rapid tooling.

•   Low-volume production of castings.

This enables customers to review the structural performance, the compatibility of the components, and the thermal considerations before committing to the production of the full volume.

Precision CNC Machining of Aluminum Die-Cast Parts

Most aluminum die-cast components for new energy vehicles require additional machining to create precision interfaces that are functionally satisfactory.

Commonly machined features are:

•   Sealing surfaces

•   Bearing bores

•   Mounting holes

•   Alignment references

•   Precision assembly interfaces

KT has the capability of multi-axis machining, such as:

•   3-axis machining

•   4-axis machining

•   5-axis machining

For features that are critical machined, precision can be reached within the range of ±0.01 mm to ±0.05 mm based on component design, material condition, and the requirements of inspection.

Dimensional Inspection and Quality Control

Automotive components demand and require consistency. KT implements thorough and systematic quality control for both the casting and machining processes.

The following outlines the stages of inspection and the associated methods:

Inspection Stage	Method	Purpose
Examination of Raw Material	Alloy Identification and Input Inspection	Checks consistency of materials
Die Casting Procedure Control	Parameter Inspection and Sight Control	Establishes control for the stability of die cast
Inspection of CNC Machining	Measurement During Machining	Defines control for critical dimensions
CMM Inspection	Verification of coordinate measuring machine	Ensures geometric precision
Final Inspection	Checks for all dimensions and visual appearance	Checks compliance for shipment

The following outlines requirements for accuracy and tolerance:

Manufacturing Stage	Tolerance Level	Use
General As-Cast Features	± 0.2 mm to ± 0.5 mm	Standard dimensions for cast
Precision As-Cast Features	± 0.1 mm to ± 0.3 mm	Controlled Tooling
CNC Machined Features	± 0.01 mm to ± 0.05 mm	Interfaces for assembly and sealing
Large Structural Components	± 0.5 mm to ± 1.5 mm	Components forlarge battery housings

The tolerance limit is influenced by the part dimensions, choice of alloy, tooling design, and manufacturing process.

Selection of Aluminum Alloys for Components in New Energy Vehicles

The choice of materials will impact how strong the components can be, how they will withstand corrosion, if they will conduct heat well, and how easily the components can be manufactured.

Aluminum Alloy	Characteristics	Typical Applications
A380 / ADC12	Good balance of mechanical properties, good machinability, excellent castability	Motor housings, inverter cases, electronic enclosures
A356 / AlSi10Mg	Ductility, good corrosion resistance, can be treated thermally	Structural components, battery tray supports
AlSi10MnMg	Good strength and crash performance	Lightweight structural automotive parts
Aluminum Thermal Alloys	Good potential for heat transfer	Heat sinks, thermal management components

KT collaborates with clients to understand the demands of the particular application and the context of use in order to choose the most suitable alloys.

Surface Finishing of Aluminum Die-Cast Components

Finishing primarily enhances corrosion resistance, aesthetics, and durability of the cast components.

Some of the more common finishing options include:

•   Anodizing

Oxide layer as finishing and protection improvement

•   Powder Coating

High performance, durable protective finishing for structural components in and related to batteries as well as exterior components.

•   Sandblasting And Polishing

Provides controlled surface texture to fulfill functional and aesthetic requirements.

•   Conversion Coating

Improves protection against corrosion and paint compatibility. Dimensional stability is retained.

The choice of finishing method is driven by the environmental conditions that the component will be subject to and client preferences.

Applications Of Aluminum Die Casting For New Energy Vehicle Components

Aluminum die casting is extensively applied in the complete range of electric vehicle systems, including:

•   Battery Systems

Lightweight, strong, and thermally manage structures are required for battery trays, covers, and battery systems housings.

•   Motor And Inverter Housing

These systems require stability of the structure and good performance of heat transfer as well as high precision of the interfaces to be machined.

•   Enclosures for On-Board Chargers and DC-DC Converters

Aluminum housings are used for mechanical protection, electromagnetic shielding, and thermal management.

•   Structural Brackets and Mounts

Die-cast aluminum brackets help reduce vehicle weight and provide dependable positioning of components.

•   Heat Dissipation Components

Aluminum heat sinks and other cooling components utilize aluminum's thermal conductivity for control of electronic component temperatures.

Why Select KT For New Energy Vehicle Parts Manufacturing

KT (KING TOOL) provides an all-in-one service package for the automotive industry that includes:

•   Die casting for aluminum parts

•   Development for die casting tools

•   CNC machining with precision

•   Finishing for surfaces

•   Inspection of quality

•   Validation of prototypes

•   Support for mass production

Answers for our customers' challenges with the design of new energy vehicle parts are provided by our extensive experience with manufacturing and our DFM engineering support.

Final Observations

Lightweight aluminum die casting provides an efficient solution for manufacturing modern electric vehicle components. Combined with precision CNC machining and strict quality control, it enables new energy vehicle parts to achieve the required performance, durability, and accuracy.

KT provides complete manufacturing services to automotive clients. These services include pulling the entire process together facilitated by our tooling and manufacturing capabilities. Our customers can build dependable automotive parts and adjust to the evolving requirements of the EV sector.

FAQs

Q1. What die casting alloys does KT use for EV parts?

KT leverages A380, ADC12, A356, and AlSi10MnMg aluminum alloys for die casting.

Q2. What are the advantages of aluminum die casting for new energy vehicle parts?

Aluminum die casting is lightweight and allows for complex parts with fast production for high volumes.

Q3. What are die-cast aluminum parts tolerances?

As-cast tolerances are generally ±0.1 mm to 0.5 mm. However, NC machining can achieve tolerances of ±0.01 mm to 0.05 mm.

Q4. Can KT perform die casting and machining?

Yes, all aluminum die casting, machining, tooling, and finishing processes are available at KT.

Q5. What EV parts can aluminum die casting manufacture?

Aluminum die casting can make battery housings, motor cases, inverters, and brackets.