Automotive OEMs are increasingly turning to aluminum die casting as an affordable and low-cost manufacturing solution in the early 2020s. This is due to the increasing demand for lightweight, safe, and cost-effective vehicles.
Furthermore, the production of smaller and more compact vehicles is also driving this demand. With this in mind, the automotive industry has already started making inroads into the adoption of aluminum die casting.
Automotive OEMs Adopt Aluminum Die Casting
As a base metal for automobile components and frameworks, steel was used in the past. Yet, in recent years, aluminum has overtaken steel because of its benefits for manufacturers and users. Die casting aluminum alloy has a number of advantages for manufacturers as well as automobile users. This is why aluminum is increasingly used in automotive components and frameworks. The following are some of the reasons why aluminum is becoming more popular in the automotive oem die casting:
- With steel as the metal base, old automobiles corrode, and even luxurious cars require special attention to prevent corrosion. Even though steel is a strong material, it is susceptible to rust. That is why the automotive industry began to adopt aluminum oem die casting because it is less prone to rusting than steel.
- Aluminum is easier to shape, allowing for more intricate designs in vehicle components and frame sections.
- Aluminum oem die casting is more cost effective since it involves less labor to design and manufacture products.
- The manufacturers can make fine components with smooth inner and outer surfaces because of the easy molding feature. This feature allows the components to slide more smoothly over one another. Specifically, aluminum engine components last longer and reduce engine noise. Less friction also keeps the engine and other components cool.
- Aluminum is lightweight, which explains why light weight components and framework save money on fuel. Because of aluminum oem die casting, luxury car manufacturers can now make luxury vehicles with lower fuel consumption.
Production of Aluminum Die Castings Will Grow at CAGR of ~6%
With the rapid growth of industries in developing economies, the number of people with a consumption of aluminum is increasing. With more than 60 million metric tons of aluminum produced worldwide in 2018, die-casting machines will see an increase in demand along with the rise in aluminum per capita consumption.
It is forecast that the global aluminum die casting machine market will reach USD 1.5 billion by 2030, showing a CAGR of 6% between 2022 and 2030. There is a growing market for aluminum die-casting machines globally because aluminum is increasingly used in the aerospace, automotive, construction, and power industries. The properties of aluminum make it more suitable for use in automotive manufacturing than steel. Even though steel costs less, it is heavier. This results in a lower fuel economy. Aluminum die-casting machines consume less energy than steel die-casting machines, which propels their market expansion. Aluminum is also easily recyclable, which contributes to its popularity.
Cost-effective Manufacturing Solution
Automobile manufacturing costs continue to rise due to changes in raw material prices and the need for manufacturers to keep up with technological advances. To keep competitive and gain greater profitability, many manufacturers are putting a greater emphasis on reducing costs.
For the automotive industry to decrease expenses and save money, a cost-effective manufacturing solution is important.
- Reduce material costs
Raw materials account for about half of the total cost of an automobile, making them one of the most significant cost factors in the industry. Instead of simply preserving their old supplier connections, manufacturers should look around for suppliers who can give the best price to address this issue. With the industry turning to aluminum, which is twice as expensive as steel but considerably lighter, lowering the cost of materials will become even more important, therefore automakers must begin making procurement decisions and beginning discussions right once.
- Cooperation and collaboration
In order to effectively deliver a product that meets customers’ needs and wants, manufacturers should work closely with suppliers as well as customers. In order to ensure customers’ demands are incorporated into the rest of the development process and the supply chain, this collaboration should begin as early as possible when developing a new vehicle or product. As a result, manufacturers will not waste time and money developing products that customers won’t find appealing and will be able to make wise purchasing decisions.
- Consider the influence of workers
In order to reduce cost of production, it is important to have a highly skilled and trained workforce. Reduced employee errors and increased employee engagement for automotive work, as well as trained personnel, will all help a company save money while boosting employee satisfaction and safety.
Increased Demand for Lightweight, Safe and Cost-effective Vehicles
There was a time when we didn’t have GPS, side air bags, or seat warmers in our cars. However, it is now very common. However, having too many car functions has its drawbacks. Our vehicles typically gain weight as a result of more powerful engines, higher safety, expanded roominess, improved climate control, and less road noise. Nowadays, people also demand improved gas mileage. Governments are also taking steps to ensure decent air quality by establishing emission-control rules. That is a significant problem for the transportation industry, which must continue to improve efficiency while maintaining the safety and comfort of our vehicles, trucks, and planes. What strategies will transportation manufacturers employ? How will they strike a balance between developing low-emission, fuel-efficient lightweight automobiles and meeting consumers’ growing demands for a vehicle that is safe, comfortable, and cost effective? Using new technology and alternative materials in the body structure is part of the solution. Lightweight materials like aluminum, steel alloys, polymers, and carbon fiber are used throughout the vehicle by original equipment manufacturers, or OEMs.
It’s no secret that lightweight materials are increasingly being used in engine and mechanical components in automobiles due to their multiple benefits, including greater energy efficiency, enhanced safety, and improved performance.
- Lightweight materials have a lot of potential for improving vehicle efficiency because it requires less energy to accelerate a lighter object than a heavy one. The weight of the vehicle can be reduced by 10% to improve its fuel economy by 6% to 8%. With aluminum (Al) alloys replacing cast iron and traditional steel components, a vehicle’s body and chassis can be lighter by up to 50%, resulting in a lower fuel consumption.
- The use of lightweight structural materials makes it possible to add advanced emission control systems, safety devices, and embedded electronic systems to cars without increasing their overall weight.
- For hybrid electric, plug-in hybrid electric, and electric cars, lightweight materials are especially important. The use of lightweight materials in these vehicles can help counteract the weight of power components like batteries and electric motors, enhancing efficiency and extending the range of these vehicles. Alternatively, using lightweight materials could reduce the size and expense of the battery while maintaining the all-electric range of plug-in vehicles.
Automakers no longer rely on a single material to increase fuel efficiency, battery range, safety, and overall driving performance. Instead, they’re adopting a multi-material design strategy, in which the best material for the task is selected. Aluminum’s rising market penetration in the automotive industry is being driven by this design review.
Conclusion
Manufacturing companies can employ a thorough understanding of technological advancements to develop and implement technical improvements in order to make cost-effective aluminum oem die casting series while also lowering production risk. The process also enables a manufacturer to combine multiple components into a single unit, streamlining the manufacturer’s supply chain and allowing it to differentiate itself from competitors.
