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2023.4.19
Using high pressure to force a metal solution into a die casting mold and then cooling it under pressure to produce the desired shape is a kind of casting known as die casting. Die casting is among the most cutting-edge and productive approaches of producing precise components. Die casting is a method of shaping metal that does not need much, if any, cutting in order to get the desired shape. Because of qualities like their goods’ accuracy, low weight, attractiveness, etc., they find widespread use in fields as diverse as transportation, home appliances, aviation, manufacturing, and more. The most common method of casting is die casting. There are many other kinds of casting, but the most common and efficient is pressure casting, often called die casting. Here is a deep research on the automotive integrated die-casting industry: integrated die-casting is necessary, and the market space prospects are promising.
The white exterior of the automobile is one of its four primary parts. The body, the chassis, the engine, and the electrical components make up the bulk of an automobile. The car’s body is its skeleton and the primary compartment for the occupants and their belongings. Stamping/die-casting, welding, and other techniques are used to create the mostly metallic structure; The engine transfers mechanical energy to the chassis, which in turn propels the vehicle. Automobile necessities include air conditioners, displays, and other electrical components.
Changes to the auto industry’s production methods have been ushered in by the advent of integrated die-casting. Early automotive production began at Mercedes in the late 19th century, when vehicle bodywork were still mostly welded by hand in assembly lines. Mass manufacture of automobiles on assembly lines was pioneered by Fortescue in 1913, when welding technology was still in its infancy. Since 2020, when Tesla first introduced integrated die-casting for the rear base plate, it has been standard practice for the production of automobile bodywork.
Although there are still some drawbacks, the benefits of integrated die casting considerably exceed them. High upkeep expenditures are the primary drawback. Traditional repair procedures for vehicles simply call for the replacement of the affected region in the event of an accident, but integrated die-casting necessitates the replacement of all affected sections in the event of an accident, resulting in relatively expensive maintenance costs. Tesla’s integrated die-casting bottom plate is now less vulnerable to collision damage because to the low likelihood of contact. Large readjustment is the second drawback. As a relatively new manufacturing technique, integrated die-casting necessitates substantial renovations to the existing factory structure, such as the removal of stamping and welding process equipment and the installation of massive integrated die-casting machines and massive molds. However, there is a lot of room for error with integrated die-casting since technology is still in its infancy. High initial investment is the third drawback. There is a substantial initial investment for integrated die-casting since it necessitates the use of big die-casting machines (above 6000T) and huge molds with enormous tonnage.
Tesla is pioneering integrated die-casting
Tesla is at the forefront of the movement toward integrated die-casting. To begin, Tesla created an aluminum alloy formula for integrated die-casting (with the necessary materials), then patented an integrated die-casting white body (with the necessary solutions/plans/ideas), then installed the first large die-casting machine (with the necessary equipment), and finally, on Battery Day, announced the die-casting plan for the entire lower body (with clear plans for the body and chassis). The back floor’s mass manufacturing is complete (or at least functional).
The Tesla Effect: Making Automobiles as Fun as Playthings
When compared to the “stamping+welding” procedure used to mass produce huge vehicles, the process for making miniature cars is far more streamlined and effective. Hundreds of parts and dozens of stamping machines and welding robots are used in the vehicle’s “stamping+welding” mode, making it a tremendously complicated process. In order to create a white body, hundreds of uniquely shaped structural components must be pressed into tiny pieces using dozens of stamping machines. Second, hundreds of welding robots are required to join the various structural pieces together, first by welding them into smaller structural sections, and then by joining the somewhat bigger structural parts with the covering portions to create a white body. To make a white body for a toy vehicle, all you need is a casting machine and some liquid, which can be pumped into the machine.
Tesla: Heat-resistant aluminum alloy is required for integrated die-casting
Using integrated die-casting technology, Tesla has created a heat-free aluminum alloy using a proprietary recipe. On January 8, 2019, Tesla published patent “CN112567059- Aluminum alloys for die casting,” which describes a high-performance die casting aluminum alloy with high yield strength, high conductivity, high fluidity, and low hot cracking sensitivity. Aluminum alloys that don’t need to be heated in order to get the desired mechanical properties are readily available. In order to enhance their mechanical qualities, traditional aluminum alloys and other metals/alloys are routinely heated. Heat-free aluminum alloys can achieve the same effect without the need for heat treatment, thereby avoiding the issues of deformation or surface defects that are likely to occur during the heat treatment process of large die-casting parts, significantly lowering the risk of scrap and increasing the yield rate.
Tesla: Full white body construction is possible with integrated die-casting.
An whole integrated frame may be cast in a single operation using this casting equipment. On the left is a simplified representation of an embodiment of a multi-directional casting machine for a vehicle frame. The integrated frame of a vehicle (such as an electric car) may be cast in its whole or in large parts using a casting machine. The casting machine may also take the form of an integrated frame for the purpose of casting left and right sides, a roof, a floor, and/or the front and/or back of a vehicle. In such a case, casting the whole frame may need the use of numerous casting machines. In contrast, as was just mentioned, the casting machines described in this article can reduce the number of casting machines or actual castings needed to cast complete or substantially complete vehicle frames (for example, to less than six, less than five, less than four, less than three, less than two, or even one casting or casting machine). For instance, a casting machine may be adjusted such that it casts integrated body frames that are 20% complete, 40% complete, 60% complete, 80% complete, 100% complete, or any proportion in between.
Tesla: Integrated die-casting will make its way up from the lower body over time.
Tesla pioneered the use of die-cast rear flooring integration. Using an integrated forming die casting procedure, the Model Y’s whole rear body is cast in a single operation, eliminating the need for more than 70 individual pieces and resulting in a 30% reduction in vehicle weight and a 40% decrease in production costs. Integrated die casting typically begins with the bottom body. The use of integrated die-casting for the front cabin, middle floor, and rear floor was first proposed by Tesla Battery Day in September 2020. It also introduced CTC technology, which allows battery cells or modules to be installed on the vehicle body by joining the front and rear body castings and substituting the battery cover for the cabin floor.
A new age is on the horizon, and integrated die-casting is a need. The development and exploratory phases of integrated die casting have reached a critical juncture. Tesla suggested integrated die-casting, which has since been adopted by both established die-casting companies and new, disruptive players. As a result, it is now trending in the automobile sector. We anticipate that integrated die-casting, which is presently in an exploratory and developmental phase, will soon enter a period of significant expansion. The outlook for this sector is bright.
No. 1 Trend: There is a flourishing industry dedicated to creating new energy vehicles.
Production and sales of automobiles worldwide have been on an upward trajectory recently, with a high in 2017 after hovering around 95 million units. There has been a minor decline in production and sales over the previous three years, but the trend is tiny and output and sales have stayed over 80 million cars. China’s car production and sales have been showing positive growth momentum in recent years, with annual production hovering around 24 million vehicles and annual sales hovering around 25 million vehicles. Production and sales have stayed around 25 million cars after reaching a high in 2017, and although there has been a minor decreasing trend in the previous three years, the size is quite tiny. New energy vehicles have positive forward momentum, with both technological advancement and an uptick in manufacturing and sales. The compound annual growth rate (CAGR) for this market was 62.00%, taking it from 28800 cars in 2012 to 1366100 vehicles in 2020. Over the previous five years, the CAGR has achieved 27.76%, rising from 401,300 cars in 2015 to 13,661,000 vehicles in 2020.
No. 2 Trend: Low carbonization
Carbon emissions are a growing concern across the world, including in China. The issue of carbon emissions is growing more urgent as the world’s carbon dioxide output continues to rise. Significant environmental risks associated with low carbon have captured the attention of people all across the globe. The development of new energy vehicles and the demand for lightweight have both been advocated in the context of low-carbon. To curb carbon emissions, the government places a premium on the so-called “dual carbon” strategy.
No.3 Trend: Keeping It Light
The rising lightweight movement is being fueled by the low carbon demand. Increased fuel use is a major contributor to global warming, and vehicles are a major contributor to this problem. For every 100 kilograms (kg) decreased from a vehicle’s weight, fuel consumption per 100 kilometers may be lowered by 0.3 to 0.6 liters (L), and carbon dioxide emissions can be reduced by roughly 5 grams per kilometer, according to research based on experimental data. Lightweighting may decrease fuel consumption and enhance range, hence it’s important for new energy vehicles to be as lightweight as possible. Losing weight is one way to extend the range of new energy vehicles, which is important since “mileage anxiety” is a major issue for the industry right now. Experiments show that electric vehicles’ range may be extended by 2.5 kilometers for every 10 kilograms of weight they shed. There is a greater need for lightweight new energy vehicles. The engine, gearbox, etc., are the primary contributors to a vehicle’s quality while running on fossil fuels, whereas the electric motor, power battery, and electronic control system make significant contributions to the quality of a new energy vehicle. The greater mass of the three electric systems contributes to the superior quality of modern energy cars compared to fuel vehicles. As a result, there is a greater need to achieve mass reduction in alternative energy cars than there is in gasoline vehicles.
No. 4 Trend: Increased use of aluminum alloys
Increases in aluminum content for vehicle frames are fashionable, and the prospect for progress in aluminum alloys is bright. The “Roadmap for Energy Conservation and New Energy Vehicle Technology” proposes the overarching concept of gradually mastering lightweight material manufacturing technology, with an emphasis on aluminum alloys, magnesium alloys, and carbon fiber composite materials, and it provides clear guidance and plans for the use and development goals of aluminum alloys in China in 2015, 2020, and 2025.
Forecasting the size of the integrated die-casting industry: a single car’s worth is proportional to the size of the integrated die-casting market. Estimates for the integrated die-casting equipment market range from 40.5 billion yuan in 2025 to 261.4 billion yuan by 2030 (based on an optimistic sales volume estimate); 32 billion yuan in 2025 to 206.3 billion yuan by 2030 (based on a neutral sales volume estimate); and 26.4 billion yuan in 2025 to 143.2 billion yuan by 2030 (based on a conservative sales volume estimate).