China Automotive Magnesium Alloy Die Casting Industry Report Magnesium alloy is a good substitute for steel and aluminum alloy, and can reduce the product weight by 25%-75%. However, the current application ratio of magnesium alloy in automobiles is much lower than that of aluminum alloy.Get more news about magnesium alloy casting manufacturers,you can vist our website! Given energy saving, environmental protection and performance, lightweight vehicles have become one of the important directions for the development of the global automotive industry. In 2020, China released Energy-saving and New Energy Vehicle Technology Roadmap 2.0, putting forward lightweight requirements for all types of vehicles. In addition, major automakers have proposed goals of promoting the development of lightweight vehicles. At present, lightweight vehicle technology is mainly divided into three types: lightweight material technology, lightweight advanced process technology, and lightweight structure optimization technology. Lightweight materials are the key to lightweight vehicles. Magnesium alloy features low density, high strength, good heat dissipation, strong vibration resistance, noise reduction, excellent die casting performance, and outstanding cutting performance, as an ideal lightweight material. Under the trend of lightweight vehicles, the market demand for magnesium alloy will grow rapidly. In 2015, a single car in China only used about 1.5kg of magnesium, which was far lower than the level in Europe, America, Japan and other regions. However, with the rapid development of new energy vehicles and the acceleration of the lightweight vehicle process, the amount of magnesium used in a single vehicle in China has grown rapidly, and it is estimated to reach 15kg in 2020. As per Energy-saving and New Energy Vehicle Technology Roadmap 2.0, a single car in China will use 45kg of magnesium alloy, which will account for 4% of the total vehicle weight by 2030 when the Chinese automobile market will demand 1.31 million tons of magnesium alloy die casting parts with a CAGR of 13.2% in 2020-2030. For every 10% reduction in the weight of new energy vehicles, the average cruising range can increase by 5%-8%. Therefore, the demand for lightweight new energy vehicles is urgent. The density of magnesium alloy is 2/3 that of aluminum and 1/4 that of steel, so it is much lighter than the latter two, which means that magnesium alloy is the best choice for lightweight new energy vehicles. Lightweight battery packs can make outer casings, bottom trays, and inner end/side panels lighter. For example, Tesla MODEL S mainly uses aluminum alloy for the battery pack shell which weighs up to 125 kg; if it uses magnesium alloy, the weight will be reduced by about 60 kg or nearly 50%. At present, Wanfeng Meridian, Qianhe Magnesium, RSM Group, Eontec, Ka Shui Group, etc. have made layout in the field of magnesium alloy casting for battery pack shells of new energy vehicles. As the world’s leading supplier of new energy vehicle batteries, CATL has also deployed magnesium alloy die casting for battery packs. In November 2020, CATL, Sanxiang Advanced Materials, Vansun Group, and Zhuhai Hengqin Yinmei Technology jointly established Ningde Wenda Magnesium-Aluminum Technology Co., Ltd. to build a magnesium-aluminum alloy project with a total investment of RMB800 million. The products include die casting structural parts for battery casings.

The automotive industry looks for high quality and low prices. Sand casting helps them have both. It’s a process that scales well, making it cost-effective for low to high volumes. It works with a wide range of metals and is capable of high finished part quality. However, it’s not appropriate for every automotive casting. Here’s information on when it is suitable.Get more news about Sand Casting Parts,you can vist our website!

Sand Patterns
All casting involves pouring liquid metal into a cavity where it cools and solidifies. In sand casting that cavity is formed in green or resin sand. “Green” refers to the sand containing moisture from the clay binder, and not to its color. Resin sand is where the sand is coated with a resin binder.

The cavity is made in two halves. A pattern replicating half of the part being made is placed into a box and sand is packed around it. The box is turned over and the pattern removed, leaving a cavity in the sand. The process is repeated to form a cavity replicating the other half of the part in a second box.

The two boxes are stacked together and metal is poured in through a hole in the upper box. Once it solidifies, the boxes are opened and the sand broken away to reveal the cast part.
Internal cavities in the cast part are created by placing cores in the sand mold. These are removed after casting, so the patterns must be designed to make this possible.

Beneficial Characteristics of Sand Casting
The process can be automated for low-cost, high volume production
Suitable for a wide selection of materials
Green sand permeability helps reduce porosity and nonfills
Downsides to Sand Casting
Slow cooling and solidification (sand insulates,) results in a coarse microstructure
Minimum wall thickness is around 3/16”-¼”
Patterns need a draft angle of 1- 2° to release from the sand, so perfectly vertical walls aren’t practical
Parts may need considerable machining to produce tight-tolerance features like mounting holes and bores