High Quality Automotive Aluminum Die Casting Components
320 MPa Tensile Strength, Near-Zero Porosity, Guaranteed Airtightness, ±0.01mm Tolerance
CEX Automotive Aluminum Die Casting Components
At CEX Casting, we create high-performance aluminum castings for the automotive industry, focusing on strength, precision, and long-term reliability.
We specialize in aluminum high-pressure vacuum die casting and the patented squeeze casting process, producing dense, high-strength aluminum casting parts with excellent mechanical strength, sealing performance, and dimensional accuracy, widely used for auto powertrain and chassis systems.
With over 29 years of experience, in-house mold design, advanced simulation tools, and strict quality control, we provide consistent quality, fast turnaround, and trusted one-stop solutions for the global automotive industry.
CEX Capabilities in Automotive Aluminum Die Casting Parts Manufacturing
From early-stage design to final inspection, CEX offers a complete solution for automotive aluminum die casting. Our capabilities include DFM evaluation, in-house tooling, aluminum casting, heat treatment, CNC machining, surface finishing, and full range quality inspection–all under one roof.
Solving Automotive Casting Quality Issues with Our Squeeze Casting Process
Quality Issues with Automotive Aluminum Casting Parts
Automotive aluminum castings often suffer from common quality issues such as porosity, cracks, low strength, leakage, surface defects, and dimensional deviations. Our squeeze casting process is well-suited for solving these issues and meeting the strict requirements of automotive castings.
We Solve These Issues with T6 Heat-Treated Aluminum Squeeze Castings
Advanced Equipment for Automotive Aluminum Die Casting Products
Aluminum Die Casting Machine
- Machine QTY: 7 Aluminum Die Casting Machines
- Tonnage: 160T-1100T
- Maximum Size: 1.2m*0.8m
- Wall Thickness: 2mm-15mm
- Blank Tolerance: ±0.2mm
Squeeze Casting Machine
- Machine QTY: 4 Squeeze Casting Machines
- Tonnage: 300T-1100T
- Maximum Size: 1.2m*0.8m
- Wall Thickness: 4mm-15mm
- Blank Tolerance: ±0.15mm
Automated Robotic Arms
- Fast Cycle Time: ≤10 seconds per picking
- Maximum Payload: 50 kg
- Positioning Accuracy: ±0.05 mm
- Operating Range: Up to 1.8 m
- Gripper Opening Range: 80–250 mm
CNC Machining Center
- Maximum Travel: 1000 mm × 600 mm × 500 mm
- Spindle Speed: Up to 12,000 rpm
- Tolerance: ±0.01mm
- Tool Magazine: 24 tools
- Surface Roughness: Ra 0.8 μm
CNC Lathe
- Maximum Turning Diameter: 400 mm
- Maximum Workpiece Length: 600 mm
- Spindle Speed: Up to 4,000 rpm
- Tolerance: ±0.01mm
- Surface Roughness: Ra 0.8 μm
CNC Turn-Mill
- Maximum Turning Diameter: 350 mm
- Milling Spindle Speed: Up to 8,000 rpm
- Turning Spindle Speed: Up to 3,500 rpm
- Axis Control: 5-axis (Simultaneous)
- Tolerance: ±0.01mm
Quality Control and Sustainability of Automotive Aluminum Castings
ISO 9001 & IATF 16949 Certified Die Cast Supplier
Our ISO 9001 & IATF 16949-certified Quality Management System (QMS) ensures the consistent delivery of high-quality, durable automotive aluminum castings.
Through well-defined processes and advanced inspection technologies, we maintain strict quality control at every production stage, enabling real-time defect detection and corrective action.
In-House Quality Inspection Lab
- Coordinate Measuring Machine (CMM) with a measurement range of 800×1200×600 (mm) and a Maximum Permissible Error (MPE) of 3.0μm
- Video Measuring System(VMS)
- Spectrometer
- Tensile Strength Testing Machine
- Hardness Tester
- X-Ray Machine for NDT (Non-Destructive Testing)
- Leakage Testing (Water Immersion Testing & Helium Leakage Testing)
Sustainable and Safe Production
CEX Casting is certified under ISO 14001:2015 and ISO 45001:2018, demonstrating our strong commitment to workplace safety, employee well-being, and environmental responsibility. We integrate health, safety, and sustainability principles into every stage of our production, ensuring that the manufacturing of our automotive aluminum casting parts operates with minimal environmental impact and maximum care for our people.
Automotive Aluminum Squeeze Die Casting Parts We Developed
Gearbox Casting End Cover
- Material: AlSi9Cu3
- Process: Squeeze Casting
- Heat Treatment: T5
- Mechanical Properties:
- Tensile Strength: ≥280 MPa
- Yield Strength: ≥180 MPa
- Elongation: ~4%
- Hardness: 85–95 HB
- Air Tightness: no leakage under 2 MPa (20 bar) hydrostatic pressure for 5 minutes at room temperature
Engine Mount Bracket
- Material: A356
- Process: Squeeze Casting
- Heat Treatment: T6
- Mechanical Properties:
- Tensile Strength: ≥320 MPa
- Yield Strength: ≥260 MPa
- Elongation: ≥7%
- Hardness: 95–105 HB
Transmission Oil Pump Housing
- Material: A356
- Process: Squeeze Casting
- Heat Treatment: T6
- Mechanical Properties:
- Tensile Strength: ≥305MPa
- Yield Strength: ≥250 MPa
- Elongation: ≥6%
- Hardness: 90–100 HB
- Air Tightness: no leakage under 2.5 MPa (25 bar) hydrostatic pressure for 5 minutes at room temperature
Steering Knuckle
- Material: A356
- Process: Squeeze Casting
- Heat Treatment: T6
- Mechanical Properties:
- Tensile Strength: ≥310 MPa
- Yield Strength: ≥250 MPa
- Elongation: ≥8%
- Hardness: 95–105 HB
Link Arm
- Material: A356.2
- Process: Squeeze Casting
- Heat Treatment: T6
- Mechanical Properties:
- Tensile Strength: ≥310 MPa
- Yield Strength: ≥260 MPa
- Elongation: ≥8%
- Hardness: 90–100 HB
Wheel Hub Cover
- Material: ADC12
- Process: High Pressure Die Casting
- Mechanical Properties:
- Tensile Strength: ≥240 MPa
- Yield Strength: ≥120 MPa
- Elongation: ~1%
- Hardness: 80–90 HB
Transmission Cable Bracket
- Material: ADC12
- Process: High Pressure Die Casting
- Mechanical Properties:
- Tensile Strength: ≥240 MPa
- Yield Strength: ≥120 MPa
- Elongation: ~1%
- Hardness: 80–90 HB
Heat Sink for ECU
- Material: AlSi9Cu3
- Process: High Pressure Die Casting
- Mechanical Properties:
- Tensile Strength: ≥250 MPa
- Yield Strength: ≥130 MPa
- Elongation: ~2%
- Hardness: 85–95 HB
Wiper Motor Housing
- Material: ADC10
- Process: High Pressure Die Casting
- Mechanical Properties:
- Tensile Strength: ≥230 MPa
- Yield Strength: ≥110 MPa
- Elongation: ~1.5%
- Hardness: 75–85 HB
Comprehensive FAQ for Automotive Aluminum Castings
What Types of Automotive Components Are Typically Made Using Aluminum Casting?
Aluminum casting is widely used in the automotive industry for components requiring lightweight, durability, and complex geometry. Common examples include:
- Powertrain Parts: gearbox covers, oil pump housings, shift fork brackets
- Chassis and Suspension: control arms, steering knuckles, mounting brackets
- Electric Vehicle Components: motor housings, battery cooling bases
- Sealing-Critical Enclosures: transmission cases, valve blocks
High-pressure aluminum injection casting is often used for thin-walled components, while squeeze casting is preferred for structural and sealing-critical parts due to its superior density and mechanical properties.
What Is the Difference Between High Pressure Die Casting and Squeeze Casting in Automotive Applications?
Feature | High Pressure Die Casting (HPDC) | Squeeze Casting |
Injection Speed | very high | slow and controlled |
Internal Porosity | moderate to high | near-zero |
Heat Treatment (T6) | not applicable (due to porosity) | fully applicable |
Mechanical Strength | moderate | high (comparable to forging) |
Typical Use | large volume, low-stress parts | structural and pressure-tight parts |
Squeeze casting is often chosen when strength, weldability, or leak-tightness is essential in automotive aluminum castings.
Why Is Squeeze Casting Preferred for Structural and Sealing-Critical Automotive Components?
Squeeze casting offers several technical advantages:
- Near-zero porosity, allowing full T6 heat treatment
- Improved tensile strength, yield strength, and elongation
- Excellent airtightnessand fluid sealing abilities
- Weldable and machinable, making it ideal for critical assemblies
These benefits make it a preferred solution for high-performance automotive aluminum casting parts like EV motor housings and oil control systems.
What Mechanical Properties Can Be Achieved with Aluminum Squeeze Casting?
For example, when using A356 aluminum alloy with T6 heat treatment, squeeze castings typically deliver:
- Tensile Strength: 260–320 MPa
- Yield strength: 220–260 MPa
- Elongation: 4–8%
- Hardness: 80–100 HB
These values are significantly higher than conventional high-pressure die castings, which usually cannot undergo full heat treatment due to internal porosity.
Can Squeeze Casting Aluminum Castings Be Heat Treated and Welded?
Yes, that’s a key advantage:
- T6 or T5 heat treatment can be applied without risk of crack formation
- Excellent weldability, suitable for MIG or TIG welding in automotive assembly
- No gas expansion during welding, unlike porous HPDC parts
- Consistent mechanical properties after welding or machining
This makes squeeze casting ideal for safety-critical and welded aluminum components in automotive systems.
How Is Leakage Prevented in Automotive Aluminum Castings?
Leakage in aluminum die castings is often caused by porosity, cold shuts, or cracks. To prevent this, we apply:
- The squeeze casting process, which eliminates internal shrinkage porosity
- Optimized gating, venting, and cooling design, validated by simulation
- Vacuum degassing and ceramic filtering during melt treatment
- Precision machining on sealing surfaces to achieve tight tolerances
These practices ensure that our automotive aluminum casting parts meet the demanding sealing requirements in EV cooling, brake, and transmission systems.
What Leak Test Methods Are Commonly Used for Automotive Aluminum Castings?
Leak tests are selected based on part function and pressure rating. Common methods include:
- Air Under Water: simple and cost-effective; detects visible bubbles
- Pressure Decay Test: detects pressure loss over time; widely used for housings
- Water Pressure Test: simulates operating pressure; typical for pump and hydraulic covers
- Helium Leak Detection: detects micro leaks, ideal for EV or fuel system parts
All tests are performed according to customer requirements and are standard for sealing-critical aluminum castings.
What Dimensional Accuracy Can Be Achieved with Aluminum Casting and Machining?
Accuracy depends on the process stage:
- As-Cast Tolerance (HPDC): ±0.20 mm
- As-Cast Tolerance (Squeeze Casting): ±0.15 mm
- Post-Machining Accuracy: ±0.01mm for critical surfaces
- Hole Position Tolerance (Machined): ±0.03 mm typical
- Flatness and Surface Roughness: up to Ra 8 μm for sealing faces
All automotive aluminum die castings are inspected using CMM and calibrated gauges to meet GD&T and customer specs.
How Does CEX Casting Control Internal Porosity in Automotive Aluminum Castings?
We implement strict controls across casting and melting processes:
- Use of squeeze casting or vacuum-assisted HPDC to reduce air entrapment
- Centralized alloy smelting system, equipped with degassing and deslagging devices
- Gate and vent design optimization, based on mold flow simulation
- Optional X-ray inspection for high-reliability automotive castings.
This ensures a dense and defect-free casting structure, which is critical for subsequent T6 heat treatment and leak-proof sealing needs.
What Aluminum Alloys Are Commonly Used for Automotive Castings, and Why?
Different alloys are selected based on mechanical requirements and the casting process:
- A356 (Squeeze Casting): high strength, T6 treatable, weldable
- AlSi10Mg (HPDC & SqueezeCasting): balanced strength and corrosion resistance
- AlSi9Cu3 (HPDC): good castability and thermal stability for housings
- AlSi7Mg (Squeeze): high elongation and excellent ductility
Alloys like A356 are preferred for structural and sealing-critical parts, especially where T6 heat treatment and high fatigue resistance are required.
What Surface Treatments Are Available for Automotive Aluminum Castings?
Surface finishing is critical for corrosion protection, sealing, and coating adhesion. Common treatments include:
- Shot Blasting: removes oxides and improves coating bonding
- Powder Coating or Painting: for cosmetic and corrosion resistance
- Chromate Conversion (Alodine): used before painting or sealing
- Anodizing: available on select alloys, enhances corrosion and wear resistance
- CNC Surface Finishing: Ra ≤ 8µm achievable on sealing or mating surfaces
We customize surface treatments based on the function of the automotive aluminum die casting parts and customer specifications.
How Are Aluminum Automotive Castings Inspected Before Delivery?
Each part undergoes multi-step quality inspection to ensure compliance:
- Dimensional Inspection: CMM and gauges check all critical tolerances
- Material Validation: chemical composition, tensile strength, and hardness
- Surface Inspection: checks for cracks, blisters, and inclusions
- Leak Tests: air, water, or helium methods for sealing parts
- NDT (X-Ray): for safety-critical parts upon request
- Documentation: includes inspection reports, material certificates, and PPAP records
All inspections are performed under our IATF 16949 certified quality system.
What Certifications and Quality Documentation Are Required for Automotive Castings?
Automotive projects usually require full compliance and traceability:
- IATF 16949:2016 certification(CEX Certified)
- PPAP documents (typically Level 3)
- IMDS declaration for material traceability
- RoHS / REACH compliance when required
- Full inspection records(CMM, leak, and mechanical testing)
- Batch-level traceability for all aluminum casting parts
These ensure that our automotive aluminum castings meet international OEM requirements and audit standards.
Can Aluminum Castings Meet High-Pressure Sealing Requirements in Automotive Systems?
Yes, our solutions include:
- Squeeze casting process to eliminate gas entrapment and improve sealing performance
- Helium leak detection and vacuum testing for critical EV and battery components
- Precision CNC machining to achieve Ra ≤ 0.8 μm and flatness ≤ 0.05 mm on sealing surfaces
- Porosity control through real-time degassing, ceramic filtration, and simulation-optimized gating
These castings are suitable for oil pumps, brake systems, and cooling modules requiring airtight aluminum casting parts.
How Do I Choose Between High Pressure Die Casting and Squeeze Casting for My Automotive Part?
Selection depends on multiple design and performance factors:
- Required strength or sealing→ Squeeze casting preferred
- Wall thickness < 2.5 mm→ HPDC is more economical
- Heat treatment needed (e.g., T6)→ Only feasible with squeeze casting
- High volume, non-critical parts→ HPDC is faster and cost-effective
- Welded or machined features→ Squeeze castings provide better integrity
We provide DFM reviews to help you select the optimal casting method based on performance and cost.