Every 100 kilograms of car weight reduction can save 0.3 liters of gasoline per 100 kilometers. Therefore, the lightweight, thin-walled, precise and toughened automotive castings have become the development trend. Aluminum alloys and magnesium alloys are ideal materials for many automotive manufacturers to “slim†their bodies due to their light weight, corrosion resistance, and ease of molding.
According to statistics, at present, the annual demand for aluminum alloy castings for automobiles in China is about 400,000 tons, and is increasing at a rate of 10% per year. The market prospects are promising.
There are a number of domestic companies that produce aluminum wheels, and some companies use metal gravity casting and low pressure casting to produce aluminum castings such as cylinder heads. However, compared with the developed countries in the automotive manufacturing industry, the gap in the manufacturing level and promotion of light metal castings in China is still significant. For example, in some automobile engines produced by some joint ventures, a considerable part of aluminum castings (such as cylinder heads, etc.) are still imported. The total output of aluminum castings for each truck with the largest domestic production capacity, such as Jiefang, Dongfeng and Nanjing Yuejin, does not exceed 10 kilograms. The amount of aluminum for the red flag sedan is the most, with 110 kilograms per vehicle (including 40 kilogram wheels). However, it is only Japan's level in the mid-1980s.
According to statistics, the aluminum consumption level in the foreign transportation industry is 26% of that of aluminum, which is only 5.7% in China.
At the same time, China’s abundant aluminum reserves (up to 1.5 billion tons, ranking first in the world) have provided the material basis for foreign companies to land on the beach. It is the coveted rapid development of China's auto market and the relatively low cost advantage of China's manufacturing industry. International auto parts manufacturers have quickened their pace of investment in China and strive to promote local production in China.
While the automotive aluminum foundry industry in China is still in the ascendant, the automobile magnesium foundry industry has just started, but it has great potential for development. Shanghai Chengtong Auto Accessories Manufacturing Co., Ltd. in China led Mr. Cheng to produce a magnesium alloy gearbox housing die casting for passenger cars. At present, several automobile foundries have also begun preliminary development work for automotive magnesium castings.
However, overall, China's automobile casting industry is still at a disadvantage in the global automotive casting market. At present, China's auto castings purchased abroad are mostly low-value products such as brakes. The cylinders and cylinder heads manufactured by Chinese companies are rarely used, let alone aluminum and magnesium automotive castings.
Therefore, related parties pointed out that it is necessary to increase the proportion of complex castings and high-tech and high-value-added castings, and to develop deep processing of casting blanks so that the castings can be used as automobile parts after mechanical processing, thereby increasing the added value. Only in this way can we enter the automotive OEM market on the basis of having entered the after-sales service market for foreign automakers; we can enter the complex high value-added automotive casting market and pass it on the basis of entering its general auto casting market. Mechanically processed automotive parts market; entering the supply chain sequence of multinational buyers of auto parts.
In addition, with the rising prices of raw materials, the improvement of labor compensation and social security, and the increase in environmental protection investment, the competitive advantage of low casting prices in China will be affected. Relevant persons pointed out that this is a problem that we cannot ignore in the process of product structure adjustment.
One-third of global aluminum alloys are used in automobiles. Automakers demand that aluminum castings be developed in the direction of thin walls, complex shapes, high strength and high quality. Some experts pointed out that our company should further optimize the casting process and carry out Application research and process development of new alloy materials; production costs should be reduced from the perspective of design and process, such as the use of single-mold and multi-piece technology and automation technology to increase productivity and extend the service life of the mold, and adopt an integrated design to reduce the number of parts; The use of computer simulation technology will shorten the development cycle of the process plan; the utilization of recycled aluminum resources should be emphasized, technologies for effective separation of aluminum from waste materials of composite materials and dissimilar materials must be developed, and an extensive waste recycling system should be established.
In addition, we must use high technology to transform traditional casting processes, make more efficient use of resources, save energy, save raw materials, and be environmentally friendly. For example, the use of efficient, energy-efficient smelting equipment, the use of clean, environmentally-friendly refining technology. In the new product development and trial stage of aluminum and magnesium castings, advanced parallel development technology, computer-assisted technology, process simulation optimization technology, rapid prototyping trial technology, and rapid mold manufacturing technology shall be used to establish a management information system for enterprises. Our automotive aluminum and magnesium casting companies have become highly efficient, flexible, and clean, and have constantly improved their market competitiveness.
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