Ultimate Guide to Auto Parts Casting

16th October, 2024

Auto casting is key to automotive manufacturing. EATHU is a leader in automotive parts casting. Over the years, we’ve worked with many of the renowned players in the industry, having established business relationships all around the world. Auto casting components are essential to the functionality and reliability of vehicles. 


At EATHU, we are proud of being a casting manufacturer that boasts a highly developed production process. Here, we’ll give you a complete guide to Auto Parts Casting, and hope it helps.


guide-to-auto-parts-casting


Purpose of Auto Casting

Casting is the most commonly deployed method for the production of auto parts components. Different casting methods can produce various complex-shaped automotive castings. Auto parts with really complicated shapes can only be manufactured by casting.


As the casting technology continues to develop, the application range of castings is expanding rapidly.  Forgings used previously have been gradually replaced by castings, which is a great improvement.


Main characteristics of auto parts castings include complicated shapes. Lightweight, reliability, great accuracy, and huge production capacity.


Auto Casting Materials

The main six materials used in auto castings are gray iron, ductile iron, vermicular iron, austempered ductile iron, and aluminum zinc alloy.


Automobile Gray Iron

Cylinder block is a great example of gray iron castings. Factors that are taken into considerations are thin walls and great strength. 


Low-carbon

By reducing the content of C and Si, low-carbon castings boast lower costs, good tensile strengths, ductility, and shock resistance. Here are some characteristics of low-carbon castings:

  • High cost-effectiveness. Low-carbon steel is cheaper than other types of steel because there’s less carbon and other alloying elements in it.

  • Workable. Low-carbon steel is more readily available and easier to work with than higher-carbon steels. 

  • Versatility. Low-carbon steel is ideal for use in a wide range of applications, especially the automobile industry.

  • Durability. Being strong enough for structural applications, low-carbon castings have good tensile strength, ductility, and shock resistance. 

 

Ductile Iron

Ductile iron auto casting is a process that utilizes molten ductile iron to create solid metal castings. Ductile iron is a known for its strength, flexibility, and resistance to impact and deformation, used in a wide range of applications, including automotive components, pipes, and machinery parts. 

 

Vermicular iron

VG iron is a transitional form of graphite characterized by worm-like graphite with smooth, rounded edges, also known as compacted graphite cast iron. VG iron boasts several properties which make it ideal for auto parts castings, including high heat conductivity, higher fracture toughness, and a lower coefficient of thermal expansion.

 

Austempered Ductile Iron

Heat treated to improve its strength and ductility, austempered ductile iron is stronger and more ductile than regular ductile iron, and has excellent mechanical properties like toughness and machinability. Austempered Ductile Iron is also lightweight, up to three times stronger than aluminum and up to 2.3 times stiffer. 

 

Aluminum Zinc Alloy

An aluminum zinc alloy is a metal alloy that contains zinc as its base metal and higher concentrations of aluminum than traditional zinc alloys. Other elements that may be added to the alloy include magnesium and copper. It’s known for its strength, hardness, and wear resistance. 

 

Auto Casting process

Auto parts casting utilizes 3 main casting methods: Investment Casing, Sand Casting, and Die Casting.

 

Investment Casting

Investment casting, also known as lost-wax casting, is a manufacturing process that creates precise metal components with complex geometries. Investment casting has many advantages, including: 

  • Smooth finish. A smooth surface finish can be created thanks to the ceramic mold.

  • Tight tolerances. Investment castings usually have very tight tolerances.

  • Material variety. Investment casting can be used with a variety of materials, including aluminum, bronze, magnesium, carbon steel, and stainless steel. 

  • Complex shapes. Investment casting can produce parts with complex shapes, internal cavities, and thin walls

 

Sand Casting

Sand casting is a metal casting process that utilizes sand as the mold material. Being one of the oldest and most widely used casting methods, it boasts great versatility and cost-effectiveness. Here are the advantages of sand casting:

  • Cost-Effective. Due to the fact that the materials used for sand casting are inexpensive, it is a low-cost option for producing complex shapes.

  • Versatility. It can be used to cast a wide range of metals and alloys, accommodating various sizes and complexities.

  • Flexibility in Design. The mold can be easily modified or replaced for different designs, allowing for quick changes in production.

  • Surface Finish. While not as smooth as some other processes, sand casting can produce a satisfactory surface finish, especially with proper mold preparation.

 

Die Casting

Die casting is a manufacturing process used to produce metal parts by forcing molten metal into a mold cavity under high pressure. This technique is commonly used for metals like aluminum, zinc, and magnesium. Die casting offers several advantages that make it a popular choice for manufacturing metal parts.

  • High Precision. Die casting produces parts with excellent dimensional accuracy and consistency, reducing the need for extensive machining.

  • Smooth Surface Finish. The process often results in a smooth surface finish, reducing the need for additional finishing processes.

  • Rapid Production. Die casting can produce large quantities of parts quickly, making it efficient for mass production.

  • Material Efficiency: Minimal waste is generated during the process, and excess material can often be recycled.

  • Strength and Durability: The parts produced are generally strong and durable, often outperforming components made by other methods.

  • Cost-Effectiveness: For high-volume production, die casting can be more cost-effective than other metalworking processes, despite higher initial tooling costs.

 

EATHU Auto Castings Services

EATHU Auto Parts has been a trusted name in the industry since its establishment in 1999, bringing over two decades of expertise to the art of auto parts casting. Our long history not only reflects our commitment to quality but also our ability to adapt and innovate in a rapidly changing market.

 

One of our key strengths lies in our optimized supply chain, which allows us to streamline processes and reduce lead times without sacrificing quality. This efficiency translates into competitive pricing, making us an attractive choice for businesses seeking value without compromising on the excellence of their components.

 

At EATHU, we pride ourselves on the superior quality of our products. Each casting is crafted with precision, ensuring that our auto parts meet the highest industry standards. Our dedication to excellence has earned us a loyal customer base, as we continue to deliver reliable solutions that drive success for our partners. Choose EATHU Auto Parts for unparalleled service and a legacy of quality you can trust.








Article Navigation

OTHERS YOU MIGHT WANT TO KNOW

Casting Service

Foundry

ARTICLES of AUTO PARTS CASTING

We are here to provide you with information about auto parts casting. We will keep you updated, as well as real-time updates on EATHU's news. Feel free to contact us for proposals and quotations.


8th October, 2024

Save Money: Things You Must Know Before Purchasing Valves!

Valve material is also a variety of materials, including cast iron, cast steel, stainless steel, chrome molybdenum steel, chrome molybdenum vanadium steel, duplex steel, plastics, and so on, and can even be customized non-standard! When purchasing and selecting valves, the following technical points should not be ignored:

27th September, 2024

How Does a Knife Gate Valve Work?

EATHU Valve has many years of experience in the valve industry, I use this article for you to explain the working principle of knife gate valve, if you have want to know more or want to discuss with us about the valve field stuff, welcome to contact me!

8th May, 2024

Cast Iron Valves VS Cast Steel Valves

Valves according to the material can be divided into cast iron valves, cast steel valves, stainless steel valves (201, 304, 316, etc.)。Here, Eathu answers your questions about the differences between cast iron and cast steel valves.

Write a Review

  • Name*
  • Email*
  • Rating
  • Comment*

Leave a Message

  • Could I Have Your Name?
  • Name*
  • How Could I Contact You More Convenient?
  • Email*
  • Phone
  • Whatsapp
  • You can upload parameters or drawings here.
    (Only in jpg, png, zip format, the file size is with in 2M)
  • Could you tell me the kind of support you hope to get?
  • Message*