Die casting is the cornerstone of modern car manufacturing. With aluminum alloys as the base metal, aluminium pressure die casting helps to create complex parts with high precision and the best possible dimensional accuracy. Pressure die casting, the widely used die casting process, provides two options: High-Pressure Die Casting (HPDC) and Low-Pressure Die Casting (LPDC). These two processes have their respective advantages. Output rate, manufacturing quality, and overhead expenses are also different in these two pressure die casting processes.
The high-pressure die casting (HPDC)
HPDC is one of the most applied die casting processes in the automotive parts die casting sector. In this process, molten aluminium is injected into a steel die at an immense force. The force typically ranges from 70 to 1000 MPa. This process helps to create parts with tight tolerances, thin walls, and even surface finish.
Top-grade die casting manufacturers like Rockman have developed state-of-the-art HPDC infrastructure. Here is what makes this process one of the most applied processes for automotive components manufacturing:
- High Production Rates: HPDC provides the quickest possible output. This aluminium pressure die casting process is ideal for the mass production of various automotive components such as engine blocks and cylinder heads.
- Strength and durability: With high pressure, it’s possible to develop a denser microstructure in the cast parts. It brings superior strength and high fatigue resistance. This is important for strong and durable engine components, suspension components, and several other components.
- Dimensional accuracy: HPDC is also known for the dimensional accuracy of the output. In this aluminium pressure die casting process, tight tolerances are achievable necessitating less post-machining.
- Lightweight advantage: Aluminium is a lightweight material and HPDC allows for thin walls further reducing the weight of automotive parts. The lesser the weight of the vehicle, the better is its fuel efficiency.
The Low-Pressure Die Casting (LPDC)
LPDC is a contrasting approach where significantly low pressure is created in the process. A die is designed as per the design of the automotive part. Then, the molten aluminium is injected into the die at a lower pressure ranging between 0.1 -0.7MPa. Unlike HPDC, LPDC creates a slower filling process with several advantages. Take a look:
- Complicated shapes: In the matter of manufacturing automotive parts with complicated shapes, LPDC is the first preference of die casting experts. It’s an efficient process for manufacturing automotive parts with thin walls and tight corners.
- Reduced porosity: The slower filling process removes air trapped inside the die resulting in forming automotive parts with less or no porosity.
- Castability of inserts: LPDC is an ideal process for integrating the inserts. This reduces time and steps in the assembling process.
- Reduced stress on the die: The lower pressure and slower injection of aluminium alloys minimize the stress on the die. The process allows more cost-effective tooling.
Choosing the process
Selecting the process depends on the type of the parts and the rate of output required. The team of experts decides on the matter after discussing it with the client. Rockman has infrastructure and expertise in both processes. They use fully automated HPDC and LPDC machines in different units in India. Their products have a huge demand in the international market.
- HPDC is preferred when the clients need speed, strength, and dimensional accuracy. It’s an ideal aluminium pressure die casting process for manufacturing engine blocks, structural components, and several other automotive parts in high quantities.
- LPDC is preferred when the auto parts are intricate or require inserts. Transmission housings, intricate brackets, and other intricate parts are manufactured with this process.
Rockman is a pioneer in both these processes having the required capacity to handle mass production and shaping customized parts for specific automotive designs.
