High Quality Automotive Casting Parts

uality-issues-with-automotive-castings

Quality Issues with Automotive Castings

  • Porosity and Cracks
  • Lower Strength and Hardness
  • Leakage
  • Surface Defects 
  • Dimensional Deviations
  • Impurities and Inclusions

 

We Solve These Problems Using T6 Treated Aluminum Squeeze Castings

  • We use squeeze casting technology to effectively eliminate shrinkage porosity inside castings, resulting in an exceptionally dense casting structure. This structure makes T6 heat treatment and welding process possible.

  • Due to the elimination of internal porosity, our aluminum castings can undergo T6 treatment to achieve extremely high strength and hardness. After testing, its hardness is very close to that of forged aluminum parts.

  • We have developed aluminum squeeze castings for applications operating under high pressures, capable of functioning reliably at pressures of up to 30 MPa, and meeting the leakage testing requirements.

  • We produce our castings in strict accordance with IATF 16949 quality management system. The dedicated testing laboratory specifically for automotive aluminum castings allows us to conduct comprehensive tests.

Surface Finish for Automotive Parts

The surface finish of automotive components plays a vital role in both the aesthetic appeal and anti-corrosion characteristics of the surface. We apply different surface treatment methods to accomplish this objective.

  • Anodizing 
  • Powder Coating
  • Spray Coating
  • Sandblasting
  • Shot Blasting
  • Electroplating
  • Passivation

 

Surface-Finishing-for-Automotive-Parts
nhanced-Mechanical-Performance-of-Automotive-Castings

Enhanced Mechanical Performance of Automotive Castings

We employ aluminum squeeze die casting to produce high-strength aluminum castings for automotive applications. These castings exhibit exceptional mechanical performance. They are also competitive with conventional aluminum die castings in terms of cost and offer advantages for large-scale production compared to other manufacturing processes.

Here are the mechanical properties achievable with our aluminum castings:

  • Tensile Strength:   220-270MPa
  • Yield Strength:       260-320MPa
  • Hardness:               80-95Hb
  • Elongation:             4-10%

Leakage Testing for Automotive Castings

Many automotive components have to withstand pressures ranging from a few bars to several MPa. These components requires 100% leakage test and periodic burst test.

We have the capability to design and manufacture specialized tools for conducting both leakage and burst tests. Our approach combines manual and automated testing methods, enabling us to comprehensively evaluate the pressure resistance of aluminum castings.

We have successfully developed pressure resistant automotive parts and undergone both leakage and burst tests, meeting the exacting standards specified by our customers.

Leak-Testing-for-Automotive-Castings
ISO9000-IATF16949-Certified

ISO 9001 & IATF 16949 Certified

We have established a comprehensive Quality Management System (QMS) in accordance with ISO 9001 and IATF 16949 standards. This enables us to deliver high-quality, reliable, and durable automotive parts to our valued customers.

Within our QMS, we have defined and documented robust processes and procedures that cover all aspects of product development, manufacturing, and delivery.

Our QMS incorporates various quality control measures at every stage of the production process.

We utilize advanced inspection techniques and equipment to detect any deviations or defects, allowing us to take prompt corrective actions.

Materials Used for Automotive Parts

Several commonly used materials for our developed automotive parts include:

Aluminum Alloy: ADC12, A380, A383, A356, A356.2,A413,A535

Zinc Alloy: Zamak 3 (ZnAl4), Zamak 5 (ZnAl4Cu1), Zamak 2 (ZnAl4Cu3), ZA-8 (ZnAl8Cu1)

Plastic: Nylon, PP, PU, PC, PE, PET, ABS

Key Considerations for the Manufacturing of Automotive Parts

Safety and Reliability:

Automotive components are subject to stringent safety and reliability requirements due to their critical role in vehicle performance. It is essential to ensure that automotive parts meet industry-specific standards and regulations to ensure the safety of the vehicle and its occupants.

Durability and Longevity:

Automotive components are exposed to various environmental factors, including temperature variations, moisture, and vibration. They need to withstand these conditions and maintain their performance over an extended period. Material selection and design considerations should prioritize durability and longevity.

Quality and Consistency:

The automotive industry demands high-quality components that consistently meet strict specifications. Quality control measures and robust manufacturing processes are key to ensuring stable and reliable manufacturing performance of automotive parts.

Industry-Specific Standards:

The automotive industry has its own set of standards and requirements that may differ from other industries. It is essential to be familiar with automotive-specific standards, such as IATF 16949, which focuses on quality management systems in the automotive sector.

Regulatory Compliance:

Automotive components comply with industry-specific regulatory standards and certifications, such as emissions regulations and safety standards. Manufacturers need to stay updated with the latest regulations and ensure compliance throughout the production process.

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