HOW Different Aspects of the Product Portfolio Influence the Way aluminum die casting Is Employed in Automotive Casting

When you think of aluminum die casting, do you picture large, cumbersome components with thick wall sections? In that case, you are not the only one

When you think of aluminum die casting, do you picture large, cumbersome components with thick wall sections? In that case, you are not the only one. Don't worry, we did too! What if I told you that we now have the ability to cast aluminum parts that are almost as lightweight as their magnesium counterparts, while also offering additional benefits such as higher tensile strength and additional finishing options? Would you be interested in hearing about this? Die casting in aluminum used to be avoided by design engineers because it required thicker wall sections (typically 1.5mm – 2.0mm), which resulted in heavier parts. Today, die casting in aluminum is becoming increasingly popular. Die casting in aluminum now allows for wall sections to be significantly thinner than in the past.

The primary factor that has been responsible for the expansion of the aluminum foundry industry over the course of the previous fifty years or so has been the use of castings made of aluminum in place of a variety of engine and gearbox components. The final major factor that led to a significant rise in the market demand for aluminum castings was the production of engine blocks and gearboxes in the early 1980s. This was the final major contributor to the rise in demand. In the meantime, the overall procedure for this particular replacement has been finished. This method is now widely used throughout the world, including in all of the other regions in addition to Europe. It is not anticipated that there will be an increase in demand for aluminum die cast components in the sector of engines and transmissions as a result o

f substitution. This is because substitution is expected to result in the reduction of demand.

The automotive industry is a primary contributor to carbon dioxide emissions and is currently under a great deal of pressure to significantly reduce those emissions as a direct result of global demands. E-mobility and weight reduction are the levers that, at the moment, have the greatest potential to contribute to a reduction in CO2 emissions. This is because e-mobility and weight reduction both involve the use of electricity.

People are of the opinion that the most significant shift in the aluminum product portfolio that has taken place in the last hundred years will most likely take place in the aluminum foundry sector as a direct result of the recent development that has taken place. The workhorse components of the engine and transmission space are going to be phased out, and in their place, new power train components are going to be developed. This change will take place over the course of the next few years. In spite of the significant shift that has taken place in the market, there is still the opportunity for expansion in the structural and chassis component markets, as well as in the market for aluminum casting, in the years to come. Both of these markets have the capacity to experience expansion when combined.

An Investigation into the Growing Demand for Chassis and Structural Components

The substantial realignment of the portfolio that is being brought about as a result of the expansion of these componentsIn comparison, the products that were once fabricated from steel are now produced using metals that are a great deal lighter. In order to manufacture larger chassis and structural components, it is now necessary to have equipment units that have greater clamping forces. This is the case because larger chassis and structural components require more space. For this reason, major die casters have already begun offering casting equipment with a force of more than 3,500 tons. The heaviest equipment units weigh either exactly 5,500 tons or slightly more than that.

The following are the repercussions for casting manufacturers that these modifications to the product portfolio will have.

Significant amounts of capital invested in numerous large die casting equipment units

High costs associated with the launch of new products and the creation of new processes


The decrease in cash flow results can be attributed to the lower volumes of the present series components (engine and transmission, specifically).

Strong competition as a result of excess capabilities in the locking force ranges 1,800–2,500 to (an earlier high proportion of components for the engine and transmission).

In the not too distant future, there is going to be a significant demand for employees who have experience working in foundries as a result of several new orders.

In the end, it will be necessary to carry out cost optimization in order to ensure that these requirements are satisfied. The changes bring about opportunities in addition to the risks, and the only foundries that will be able to take advantage of these opportunities are the ones that have the appropriate technology at their disposal, in addition to the financial strength, knowledgeable employees, and strategy. The only foundries that will be able to take advantage of these opportunities are the ones that have them.


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