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Die Casting News

Video-High Integrity Die Casting: The market, Applications and Commercial Aspects

Posted by Hill and Griffith Company on Aug 8, 2019 3:19:45 PM

NADCA Video News & Information

The material presented in this video include highlights from NADCA’s online webinar - High Integrity Die Casting: The Market, Applications and Commercial Aspects of High Integrity Die Casting. In this webinar the rapidly growing market for high integrity die castings is presented and applications in the various market segments are discussed. The main growth sector is automotive, where there are increased car body applications like shock towers. This is not the only market segment where structural high integrity die castings are increasingly used. We can find structural high integrity die castings more in motorcycles, recreational vehicles and also boats.

NADCA Die Cast Video Clip

Now, where that path is going to change a little bit in terms of material mix and process mix, we see more sheet and extrusions coming in, and that's what we're going to look at. So North American vehicle content, we see here the latest numbers and that is now the positive scenario that Ducker is considering. So we think that by 2025 we're at 520 pounds per light vehicle in North America. And then by 2028 we will reach 565 pounds per vehicle.

Now this one I took from a presentation from Mark White from Jaguar Land Rover and I really liked it. When he presented that and said, you know, if we look at current steel bodies, let's say they weigh about 400 kilos ... Well, he's European, so it's in kilos. And that's our baseline. That's 100%. If I use Optimized Steel, so advanced, high strength steels and ultra high strength steels, wherever it makes sense, I can save between 10 and 20% of the weight. So I could get down, let's say to 320 kilos, and my costs will be about 120%, so 20% higher than the mild steel or optimized, whatever, current steel makes.

If I switched to aluminum, I can actually save about 40%. Now a lot of people will say, okay, well, but the density is only 1/3, but mind that the strength is also much lower than steel, and you can save 60% or 70% like that. Overall, I think a 40% savings is a lot more realistic, so you get down from 400 to 240 kilos, and it will cost you probably between 50% and 100% more, so about 50% more I think is quite realistic. And in the meantime, I know that Ford even said that even though the material costs are slightly higher, they can actually save on the assembly costs. So maybe it's even a little less than 50% added costs for that 40% weight saving.

If I went to magnesium, and of course nobody would make a complete magnesium car body, but you could save actually 50%, but your costs would be between factor 2 and factor 5, and that's the thing with carbon fiber reinforced plastics today. So typical Formula 1 type car body will save you 60% and maybe even longer term more, but it will cost you five to ten times the price of a current car body.

So that's why really he says you get the biggest bang for the buck if you go with aluminum wherever it makes sense. That's why we can see a lot of aluminum in Jaguars and Land Rovers today.

For information on purchasing a downloadable copy of this NADCA webinar in its entirety, please visit: http://www.diecasting.org/store/detail.aspx?id=WEB169

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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight