Aluminium Casting: A Blessing to The Automotive Sector

Renowned automakers including passenger cars, EVs, sports cars, luxury cars, and motorcycle manufacturers use aluminium casting products in manufacturing. Aluminium die casting has emerged as the game changer in the modern automotive industry. Its advantages are proven and outstanding. 

Two aspects of aluminium die casting are critical to the modern automotive industry. First, the use of various aluminium alloys that are found to be much better than steel and offer better performance of the vehicles. Second, the die-casting process itself. The process has made many complicated designs possible supporting the technological advancement in the automotive industry. 

Let’s discuss these two aspects in detail. 

Advantages of aluminium alloys 

The question is why common alloys and high-strength aluminium alloys like 3003,5052, 6061, or 7075 are used in automotive manufacturing. Take a look: 

1. Lightweight: Aluminium casting technology has enabled OEMs and vehicle manufacturers to bring down the unsprung weight of the vehicles. For example, an aluminum wheel is almost 30% lighter than a steel wheel. Aluminium alloy parts in vehicles have reduced the weight of the engine, suspension parts, and outer body parts. Lightweight vehicles improve ride quality and reduce fuel expense per mile. 
2. Strength and Durability: Though aluminium is lighter than steel, it’s as durable as steel. Aluminium parts last long and make maintenance of the vehicles cost-effective. The strength-to-weight ratio of aluminium alloys is quite impressive, making the alloys a good alternative to steel. Manufacturers can market lightweight yet highly sturdy cars and motorcycles. 
3. Corrosion resistance: Aluminium is naturally corrosion-resistant. If an aluminium part is scratched or dented, the metal can self-repair that part by forming a protective layer of aluminium oxide. This makes aluminium a widely used material in the automotive industry. In any adverse weather condition, it can sustain reasonably well, providing vehicle owners respite from frequent expenses. 
4. Cost-effective: Aluminium is cheaper than steel. Moreover, the metal is completely recyclable. Aluminium parts are cheaper than the same categories of auto parts made of steel or other materials. 
5. Design flexibility: Die-casting is a blessing to the automotive industry. Moreover, aluminium casting has made several types of complicated designs possible. The alluring designs of sports and luxurious cars we see on the road are made possible by aluminium die-casting. 

Advantages of die-casting to the automotive sector 

Die-casting is advantageous to the automotive sector including OEMs for multiple reasons: 

1. High production rate: Die-casting is a high volume production process. In comparison to any other process, the production rate of die-casting is always high. Moreover, in the computer-aided manufacturing units, as you could see in any factory of Rockman Industries the output rate can be controlled automatically or manually. 
2. Dimensional accuracy: Die-casting processes like Low-pressure Die-Casting or High-pressure Die-casting can produce auto parts with optimal dimensional accuracy. The auto parts like alloy wheels or pistons manufactured by aluminium casting need minimum machining and finishing. 
3. Design flexibility: Die-casting processes support the creation of complex shapes and intricate designs of various auto parts. Today’s EVs or sports cars might not perform as well without aluminium die-casting auto parts. 
4. Cost-effective: The high production rate, controllable energy consumption, minimum human intervention, and reduced post-processing have made die-casting a cost-effective auto parts manufacturing process. 

Three die-casting processes 

Rockman Industries has established three die-casting processes in their manufacturing units across India. These processes include – 

1. Gravity Die-casting (GDC)
2. Low-pressure Die-casting (LPDC)
3. High-pressure Die-casting (HPDC)

GDC is the most traditional and most cost-effective die-casting process with various advantages and some disadvantages. Rockman Industries employs various aluminium casting processes for manufacturing different auto parts depending on the design accuracy, output rate, and cost-effectiveness expected.