Die casting products have become indispensable in modern manufacturing, thanks to their unique ability to balance complex design freedom, lightweight performance, and mass production efficiency. From the engine blocks powering cars to the tiny middle frames of smartphones, they penetrate every corner of industrial and consumer life—solving critical engineering challenges that other processes (e.g., forging, stamping) struggle to address. This article systematically breaks down the core application fields of die casting products, the technical logic behind their adoption, and real-world examples to help you understand why they are the first choice for thousands of manufacturers worldwide.
1. Transportation Industry: The Backbone of Power & Lightweight Innovation
The transportation sector is the largest consumer of die casting products, accounting for 60-70% of global die casting output. Its demand is driven by the need for fuel efficiency (for traditional vehicles) and range extension (for new energy vehicles, NEVs)—both of which rely on die casting’s lightweight and high-strength advantages.
1.1 Automotive: From Powertrains to Integrated Structures
Die casting products dominate automotive manufacturing, with applications covering three key systems:
- Powertrain Components: Engine blocks, transmission housings, and oil pans are typically made of aluminum alloy die castings (e.g., ADC12, A380). The rapid solidification of die casting creates a dense microstructure, improving heat dissipation by 20-30% compared to sand casting—critical for engines operating at 90-120°C. For example, BMW’s B58 engine block uses die casting to integrate 12 internal water channels, reducing weight by 15kg vs. a welded steel block.
- NEV-Specific Parts: With the rise of electric vehicles, die casting has expanded to motor shells, battery pack housings, and even integrated body structures. Tesla’s 4680 battery pack shell uses a 9000-ton large-scale die casting machine to form a single piece, eliminating 70+ welding points and reducing weight by 30kg. This not only extends vehicle range by 50-80km but also cuts assembly time by 40%.
- Chassis & Body Parts: High-strength aluminum alloy die castings (e.g., AlSi10MgMn) are used for suspension brackets and door hinges. Their tensile strength (320-350MPa) meets crash safety requirements, while their lightweight design reduces unsprung mass—improving ride comfort and handling.
1.2 Rail Transit & Aviation
- High-Speed Rail: Seat frames, door system components, and brake calipers rely on die casting’s high dimensional accuracy (tolerance ±0.1mm/m). CRRC’s Fuxing high-speed train uses die cast aluminum seat frames that weigh 40% less than steel ones, reducing energy consumption while ensuring long-term reliability (10+ years of service without deformation).
- Aerospace (Lightweight Components): While large aircraft structures still use forging, small precision parts (e.g., avionics housings, fuel system connectors) use magnesium alloy die castings. Their low density (1.74g/cm³) and excellent electromagnetic shielding make them ideal for weight-sensitive aerospace applications—Boeing’s 787 Dreamliner uses over 100 die cast magnesium parts, cutting overall weight by 500kg.
2. Electronics & Communication: Miniaturization Meets Heat Dissipation
The electronics industry’s pursuit of “thinner, lighter, more powerful” devices has made die casting products a necessity. They solve the core contradiction between compact design and functional performance—especially in heat management and signal integrity.
2.1 Consumer Electronics
- Smartphones & Tablets: The middle frame (a critical structural and functional component) is almost exclusively made of magnesium alloy die castings (e.g., AZ91D). It integrates antenna signal channels, key slots, and heat dissipation paths in a space as small as 60cm². Apple’s iPhone 15 Pro middle frame uses die casting to achieve a wall thickness of 0.8mm, while maintaining EMI (Electromagnetic Interference) shielding effectiveness of >80dB—ensuring no signal loss.
- Laptops & Wearables: Laptop shells and smartwatch cases use aluminum alloy die castings (e.g., A356) with embedded heat dissipation fins. Dell’s XPS 17 laptop shell, for example, uses die casting to form a 1mm-thin body with integrated fins—solving the thermal management problem of 45W high-performance processors without adding weight.
2.2 Communication Infrastructure
- 5G Base Stations: RF (Radio Frequency) device housings and power supply enclosures use aluminum alloy die castings (e.g., ADC12) with corrosion-resistant coatings. They must withstand harsh outdoor environments (temperature ranges of -40°C to 60°C, humidity >90%) while meeting EMI shielding requirements. Huawei’s 5G base station RF housing uses die casting to achieve an IP67 waterproof rating, ensuring no signal leakage or water damage for 5+ years.
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