Quantity: 44 sets

  Aluminum alloy die-casting products are mainly used in electronics, automobiles, motors, and some telecommunications industries. Some high-quality, high-precision, high-toughness, high-quality aluminum alloy products are also used in industries with high requirements such as large aircraft and ships. Therefore, there are relatively many requirements for the characteristics of die-cast aluminum alloy materials. The high-quality characteristics of aluminum alloy materials are also the prerequisite for maintaining the excellent quality of castings.

1. Excellent mechanical properties.

2. Good fluidity and filling

3. Good machinability

4. Generally good corrosion resistance.

5. The draft angle is small.

6. Good dimensional accuracy and stable size

7. Good surface treatment characteristics

1. Mechanical Polishing: a polishing method that obtains a smooth surface by cutting and plastic deformation of the material surface to remove the polished convex parts, such as whetstone strips, wool wheels, sandpaper, etc., mainly by manual operation. If the surface quality is high, the super-precision polishing method can be used. Super-finishing polishing is a special-purpose grinding tool, which is pressed against the processed surface of aluminum alloy die-casting parts in the polishing liquid containing abrasives for high-speed rotational movement.

2. Chemical Polishing: the aluminum alloy die-casting parts are preferentially dissolved in the microscopic convex surface of the chemical medium than the concave part, so as to obtain a smooth surface. The main advantage of this method is that it does not require complicated equipment, can polish aluminum alloy die castings with complex shapes, and can polish many aluminum alloys die castings at the same time, with high efficiency. The core problem of chemical polishing is the preparation of the polishing solution. The surface roughness obtained by chemical polishing is generally several 10 μm.

3. Electrolytic Polishing: the basic principle is the same as that of chemical polishing. The surface is smoothed by the selective dissolution of tiny protrusions on the surface of the material. Compared with chemical polishing, the effect of cathode reaction can be eliminated, and the effect is better.

4. Ultrasonic Polishing: put the aluminum alloy die-casting parts into the abrasive suspension and put them together in the ultrasonic field. By virtue of the oscillating action of the ultrasonic wave, the abrasives are ground and polished on the surface of the aluminum alloy die-casting parts. Ultrasonic processing has a small macro force and will not cause deformation of aluminum alloy die castings, but the tooling is difficult to manufacture and install. Ultrasonic processing can be combined with chemical or electrochemical methods. On the basis of solution corrosion and electrolysis, ultrasonic vibration is added to stir the solution, so that the dissolved products on the surface of the aluminum alloy die-casting parts are detached, and the corrosion or electrolyte near the surface is uniform. The cavitation effect of ultrasonic waves in the liquid can also inhibit the corrosion process and benefit the surface brightening.

5. Fluid Polishing: it depends on the high-speed flowing liquid and the abrasive particles it carries to wash the surface of the aluminum alloy die-casting to achieve the purpose of polishing. Common methods are: abrasive jet processing, liquid jet processing, hydrodynamic grinding, etc. Hydrodynamic grinding is driven by hydraulic pressure so that the liquid medium carrying abrasive particles flows back and forth at high speed across the surface of the aluminum alloy die casting. The medium is mainly made of a special compound (polymer-like substance) that flows through at a lower pressure and is mixed with abrasives. The abrasive can be silicon carbide powder.

6. Magnetic Grinding and Polishing: the use of magnetic abrasives to form abrasive brushes under the action of a magnetic field to grind aluminum alloy die castings. This method has high processing efficiency, good quality, easy control of processing conditions, and good working conditions.

Aluminum alloy A360 is an American standard aluminum ingot. Aluminum content: 88 (%), cast aluminum alloy grade: A360

• Material composition

• Mechanical properties

• Physical properties

• Application: lA360 aluminum alloy This alloy has good forming performance, corrosion resistance, candle resistance, fatigue strength and medium static strength. It can be used to manufacture automobile oil pans, automobile controller shells, motor shells, 5G communication boxes, LED lamp housing and so on.

A360 aluminum alloy aluminum ingot          

A360 aluminum alloy die casting

•   This is the first "Chuan-Chongqing Die Casting Festival" 1st Chuan&Yu Die Casting Festival will be held in Chongqing, China (Chongqing International Expo Center). From September 2 to September 27, 2020, there will be a three-day exchange in the die casting industry.

•   China Casting Technology has held 48 die-casting brotherhoods across the country since June 2018, and built a platform for offline communication between die-casting brothers across the country. Each fraternity has received positive responses and good evaluations. In view of the format and venue of the sorority, the number of participants, meeting content and schedule are limited.

•   In order to allow more die-casting friends to participate in face-to-face exchanges, face-to-face discussions, and face-to-face learning, China Casting held the first "Die Casting Festival" in Dongguan in November 2019, which has received positive responses from the die-casting brothers in Guangdong And participation, the event was a complete success. Invited by the organizer of Chongqing Lijia Exhibition, China Casting Technology will hold the die-casting festival "Sichuan-Chongqing Die-casting Festival" again in the same period of Lijia Exhibition.

•  The activities are rich in content, such as "Die-casting New Technology" seminar, "Die-casting post-processing" seminar, casting outpatient clinic, PQ actual combat exchange meeting, the 21st "Lijia Exhibition", "Die Casting People's Congress Gift Package" distribution and other interesting activities .

• Our company(EMP Die Casting) will also participate. We will participate in this event with an open-minded communication and serious study mentality, hoping to pass on our advantages and absorb good technology to improve our professionalism. Do our best to provide customers with quality products and satisfactory services.

• The following are the photos of our company's first "Die Casting Festival" event in Dongguan, Guangdong last year:

ü Benefit:

The automatic die-casting equipment itself is a machine that can quickly receive instructions system. It can use a complex control program to complete all the orders of casting production. It has the following characteristics:

（1）Improve the stability of the die casting process.

（2）The production efficiency of castings can be greatly improved.

（3）The need for the skills of operators is reduced.

（4）The labour intensity of operators will be greatly improved.

（5）The quality of castings is no longer dependent on the skills of operators to ensure product quality so that the quality of casting is stable and reliable.

ü Conditions:

Die casting automated production conditions are indispensable. If the conditions are perfect, it will bring better quality and productivity to the product, reduce production costs, and improve production efficiency. The following are the requirements:

（1）The configuration of the die casting workshop should be high, with advanced automatic die casting machines.

（2）There must be technical support from professionals to ensure the stability of the automated die casting machine.

（3）It is necessary to appropriately combine manual and mechanized production to improve efficiency and make products more detailed.

（4）In addition to equipment requirements, the demand for products is also high.

（5）There are also requirements in terms of staff quality.

• Overview: The cylinder head is made of cast iron or aluminum alloy. It is the installation base of the valve mechanism and the sealing cover of the cylinder. The good cylinder and the top of the piston from the combustion chamber.

• Structure: The cylinder head is a box-shaped part with a complex structure. Its structure depends on the cooling method of the engine, the number of valves per cylinder, the position of the camshaft, the intake and exhaust ducts and the shape of the combustion chamber. The cylinder head has a valve seat, a valve guide hole, a cylinder head bolt hole, a lubricating oil passage hole leading to the valve rocker arm, and intake and exhaust passages.

• Structural features:

1. Water-cooled cylinder heads are divided into integral type, split type and single type.

2. Air-cooled engines are all single-piece cylinder heads.

3. The integral cylinder head has a compact structure, which can shorten the centre distance of the cylinder.

4. The single-piece cylinder head has high rigidity and is superior in spare parts storage, repair and manufacturing.

• Function:

a. Provide engine lubricating oil refuelling channel to shield the cylinder head and valve mechanism to ensure that oil and gas do not leak

b. Separate the lubricating oil from the combustible mixture

c. Provide a fixed position for the camshaft position sensor, ignition coil, wiring harness and other parts

d. Reduce engine noise and vibration.

• Aluminum alloy meets the requirements of cylinder head cover, chain cover, oil pan, and other engine parts working in harsh environments due to its lightweight, high strength, good heat dissipation, and corrosion resistance. It has become the most widely used in automobiles. One of the alloy materials. The aluminum alloy must be purified, refined, refined, and altered before die-casting so that its mechanical properties and quality can reach consistency and stability.

• Overview

Die casting parts are made from the die casting process. This is a die-casting machine equipped with a casting mould to pour the heated liquid copper, zinc, aluminum or aluminum alloy into the inlet of the die-casting machine, and then die-cast it by the die-casting machine. Thereby, copper, zinc, aluminum parts or aluminum alloy parts of the shape and size restricted by the mould are cast. Such parts are usually called die casting parts.

• Application of Aluminum Die Casting Parts

Aluminum alloy die castings are a popular product in the die casting industry today. Because aluminum has the advantages of thermal conductivity and lightweight, it is widely used in automobile manufacturing, internal combustion engine, electric motor, oil pump manufacturing, electronic communication parts production, and other industries. Our company has aluminum alloy die-casting technology suitable for various industries, mainly for automotive die-casting parts and telecommunication, motor housing, electric vehicle battery housing die-casting parts, and so on.

• Summary

Because aluminum alloy has good fluidity and plasticity, and the casting process is cast in a pressure die casting machine, aluminum die castings can be made into various complex shapes, which are suitable for the production of die castings in many industries. In addition, aluminum alloy die castings can be made with higher precision and smoothness, which greatly reduces the amount of machining of the castings and the casting allowance of aluminum alloy. Therefore aluminum alloy die castings not only saves electricity and metal materials but also greatly saves labour costs.

u According to the latest research released by the American Foundry Association some time ago, the direct output value of the American metal foundry industry in 2020 can reach 44.3 billion U.S dollars, which will drive the overall U.S economy up to 110.52 billion U.S dollars.

u Metal casting is a highly modern industry with a long historical foundation and cutting-edge technology, and it is the backbone of the manufacturing economy. It is an industry with a total economic output of 110.52 billion U.S.dollars, and it, directly and indirectly, provides nearly 500,000 jobs for the United States. The die casting industry is at the core of economic growth, modern infrastructure, and the defense industry.

u Castings are critical to our country's infrastructure, national defense, and quality of life's said Doug KurKul, CEO of the American Foundry Association. This latest analysis clearly shows that the metal foundry industry how importance is our manufacturing economy and the job market.

u However, for the Chinese die casting industry, the United States has an increasing demand for the die casting industry, which has led to a continuous increase in China's castings exports and stimulated more companies to develop the foundry industry. Therefore, the increase in the output value of the American foundry industry not only has an impact on the American economy and the market but also brings more orders to China and more overseas markets.

u The following is the impact of the American die casting industry on the U.S. economy and work from the figure. It can that due to the increase in the output value of the American die casting industry, the U.S. metal casting industry has nearly 500,000 jobs each year, with total wages and benefits exceeding 32 billion U.S. dollars. The contribution to federal, state, and local taxes is approximately $10.59 billion. And at the 2020 online summit held on the Internet, the American Foundry Association published an economic impact analysis, during which die casting manufacturers and decision-makers discussed the chain effect of the die casting industry on the economy.

Ø Description:

The corrosion products generated by the aluminum alloy die castings due to the action of the medium form a layer of film, which closely covers the surface of the aluminum alloy die castings, and changed the surface state of the aluminum alloy die castings, the electrode potential of the aluminum alloy die-casting part is greatly changed in the positive direction, and becomes a passive state of corrosion resistance.

Ø Advantage:

1. After the passivation treatment, it has the characteristics of not increasing the thickness of the parts and changing the colour, which improves the precision and added value of the product and makes the operation more convenient;

2. Since the passivation process is carried out in a non-reactive state. The passivation agent can be added and used repeatedly, so life is the cost is more economical.

3. Passivation promotes the oxygen molecular structure passivation film formed on the surface of aluminum alloy die castings, the film layer is dense, the performance is stable, and it has a self-repairing effect in the air at the same time. Therefore, compared with the traditional anti-rust oil method, passivation The passivation film formed by chemical treatment is more stable and corrosion-resistant.

Ø Process:

1. The first process: pre-degreasing - main decreasing - water rinsing - water rinsing - whitening and descaling - ultrasonic cleaning -water rinsing - activation - water rinsing - water rinsing - passivation - water rinsing - water rinsing - drying. That is a relatively complete process, which is widely suitable for different passivation environments and aluminum alloy products.

2. The second process: degreasing-water rinsing - water rinsing - activation - water rinsing - water rinsing - passivation - water rinsing - water rinsing - drying. That is the process flow after aluminum alloy polishing.

3.  The third process: degreasing-water rinsing - water rinsing - passivation - water rinsing - water rinsing - drying. If the casting part is mechanically polished, the film colour is required to be natural, and the corrosion resistance is not high. For example, the neutral salt spray test requires about 48-72 hours, can try this simplified process.

4. The fourth process: degreasing-water rinsing - passivation - water rinsing - drying. If the casting parts drain well and the part structure is relatively simple, then you can choose to streamline the process flow.

1. Description

In the die casting process, the factors of pressure and insufficient clamping force, etc. It is inevitable that die casting parts will have burrs. Recently, with the increasing quality requirements of die castings, the requirements for burrs have become more strict, and methods for deburring have emerged endlessly.

2. Method

1) Manual Deburring　　

This is the most traditional and commonly used method in die casting plants, using files (files include manual files and pneumatic files), sandpaper, belt machines, grinding heads, etc. as auxiliary tools.

Application: Low technical experience for workers, suitable for aluminum alloy die castings with small burrs and simple product structure.

2) Grinding and Deburring (Vibration Grinding)

This type of deburring includes vibration, sandblasting, rollers, etc., which are currently used in many die casting plants.

Application: suitable for small aluminum alloy die castings with larger quantities in mass production.

3) Trimming　　

Use a production die to cooperate with a punch for deburring.

Application: Suitable for aluminum alloy die castings with simple parting surfaces, and the efficiency and deburring effect are better than manual.

4) Automatic Deburring

The principle is similar to manual deburring, except that the power is turned into a robot. With the support of programming technology and force control technology, flexible grinding (pressure and speed conversion) is realized, and the advantages of robot deburring are prominent. 

Most of our die-casting parts use automatic deburring, which not only saves labour costs but also improves production efficiency.

• Under the unpredictable economic situation in 2020, the new infrastructure in 7 major areas including 5G infrastructure, UHV, inter-city high-speed railway, and inter-city rail transit is expected to become the biggest “saving” economy in 2020 rely on.

As shown in the figure below, they are all communication parts of 5G base stations, including Telecommunication Cover, Telecommunication Cavity, Aluminum Casting Radiator, and Heat Sink Housing.

• According to the market research company Dell'Oro report, in the first quarter, the mobile core network equipment market grew by 10% compared with the same period last year, reaching nearly US$8 billion. Due to the deployment of the 5G core network, growth is expected to accelerate in the next four quarters.

As major communications equipment such as ZTE, Huawei, Nokia, Ericsson, and Cisco have entered a period of strong demand, die-casting parts such as telecommunications housings, heat sinks, and cavity filters have also ushered in huge market demand.

• The above is a comparison of the data of major brands. The top five suppliers in the global telecommunications equipment market in terms of revenue share in 2019 are Huawei (28%), Nokia (16%), Ericsson (14%), ZTE (10%) ) And Cisco (7%), as a comparison, the market revenue share of these five suppliers in 2018 was 28%, 17%, 14%, 8%, and 8%.

• According to the data,  it can be proved once again that 5G base stations bring greater demand to the market. Therefore, our company has increased the production capacity of die-casting plants and stimulated us to innovate more 5G telecommunication products.

• In recent years, with the frequent occurrence of automotive market price wars, cost pressures have continued to affect the supplier, causing many automotive parts manufacturer to face huge challenges in their cost control capabilities, and the problems are becoming increasingly prominent. In particular, most automotive parts manufacturers generally lack independent development capabilities, lack of core technology, extensive internal management models, and weak cost control.

• At the same time, informationization is the inevitable trend of the development of the times, automotive parts manufacturer can only further improve their management level and core competitiveness by improving their digital capabilities and realizing intelligent management.

• For the reform of automotive market, our die-casting suppliers must also keep pace with the times. Always pay attention to popular products in the automotive market, make the company closely integrate with the market, improve the company's technology and product innovation capabilities, and serve more customers.

• Recently, our company is mainly promoting the aluminum die casting parts of electric vehicles, including electric vehicle battery housing, control motor housing, AC/DC converters housing, etc. They are main products in the current electric vehicle market, and EMP is keeping up with the dynamic development of the market.

1. Multi-particles and impurities on the surface of die castings

l Reason:

A. Impurities in curing furnace

B. Dust, clothing fibres, equipment abrasive particles, and dust deposits in the powder spraying system

C. Too many powder additives, uneven pigment dispersion, or too high temperature during powder production, part of the powder has been cross-linked and solidified

D. The powder coating is damp and agglomerates, and the atomization are not well when spraying.

E. There are particles on the surface of aluminum alloy die castings before spraying

F. Too much-recycled powder added and not sieved

G. The coating is sprayed too thinly, and the substrate is difficult to cover if it is mild

l Suggestion:

a. Thoroughly clean the inner wall of the curing oven with a damp cloth and a vacuum cleaner, focusing on the gap between the hanging chain and the air duct

b. Blow the powder spraying system with air before starting work every day, and thoroughly clean the powder spraying equipment and powder spraying room with a damp cloth and a vacuum cleaner

c. Improve powder quality

d. Change warehouse conditions, do not use expired plastic powder and modify coating equipment

e. Clean up before spraying to reduce burrs on aluminum alloy die castings, etc.

f. The recycled powder added is appropriate and needs to be sieved

g. Increase the coating thickness appropriately

2. Serious orange peel on the surface of die castings after powder coating

l Reason:

A. The surface of aluminum alloy die castings are too rough and the coating is difficult to level

B. The powder size is too coarse or its self-levelling is poor

C. The coating is too thin or too thick, if it is too thin, it will show muscular wrinkles, if it is too thick, it will show orange peel

D. Electrostatic shielding, uneven coating thickness

E. The curing temperature is too low and not fully levelled

l Suggestion:

a. Use sandpaper to polish the surface and make the coating thicker

b. Use high-quality powder coatings

c. Master the powder output and spraying time to ensure the appropriate thickness (40-60μm)

d. Improve the spray gun, reduce the electrostatic shielding area as much as possible, or choose a friction spray gun

e. Increase the solidification temperature and extend the levelling time 110-135℃ for the melt levelling area

3. Poor powdering rate

l Reason:

A. The voltage is adjusted too low during spraying

B. The grounding condition of aluminum alloy die casting is not good

C. The resistance of the high voltage generator is too small and the output current is too large

D. The spraying air pressure is too large

E. The hook is insulated and the conductivity is too poor

F. The spray gun is too far away from the aluminum alloy die casting

G. Poor powder performance

l Suggestion:

a. Adjust the voltage to an appropriate value of 60-90KV

b. Add a ground wire to ensure good grounding

c. Increase the resistance of the resistor appropriately

d. Reduce the powder supply air pressure appropriately

e. Clean the hook regularly to make the conductivity good

f. Adjust the spray gun distance appropriately

g. Use high-quality powder coatings

1. Friction Stir Welding (Friction Stir Welding, FSW for short)--Using a special form of stirring head to move forward while rotating, the friction between the stirring head and the casting parts generates heat, and the heat of friction makes the metal in the part in a thermoplastic state, and under the pressure of the stirring head, the parts to be welded together to one part.

2. Advantages of friction stir welding:

• Good Welding Quality: The weld is extruded in a thermoplastic state, and belongs to solid-phase welding, which has excellent mechanical properties.

• Widely used: Not limited by shaft parts, it can be welded straight welds, fillet welds, girth welds, etc., expanding the scope of application

• No need for high operating skills and training: Friction stir welding uses automated mechanical equipment for welding, avoiding the dependence on the technical proficiency of operators, stable quality, and high repeatability.

•  No need for welding wire and a protective atmosphere: There is no need for filling materials and shielding gas during welding, no pre-treatment of the surface of the casting parts before welding, no protective measures need to be applied during the welding process, which simplifies the welding process.

• High dimension precision: Since friction stir welding is solid-phase welding, its heating process has the characteristics of high energy density and fast heat input.

• Green welding method: The friction stir welding process does not produce arc radiation, smoke and spatter, and has low noise, which realizes the environmental protection of the welding process. Therefore, friction stir welding is called the "green welding method".

3. Application:

1. The picture shows the welding process of our current motor housing:

   

   

2. Friction stir welding technology can be applied to a variety of aluminum alloys, such as pure aluminum alloy 6061, 6063, casting aluminum alloy ADC12, A380, A356, etc.

3. In the automotive field: engine, chassis, gearbox housing, motor housing, cylinder head, etc.

1. Automotive Parts Manufacturing

Automotive parts manufacturers are the first to bear the brunt. Nowadays, the development of automobiles is becoming larger and larger, and the rise of electric vehicles has led to the transformation and upgrading of many automakers, striving to develop the electric vehicle industry. Therefore, many manufacturers have been added, and our company will provide automotive parts manufacturers with aluminum alloy die-casting parts, such as Gearbox Housing, Motor Housing, Cylinder Head Cover, etc.

2. Electric Charging Station

As the power supply for new energy vehicles, charging piles are as important as the construction of gas stations across the country. With the promotion of new energy vehicles, the state and enterprises have also increased their efforts to promote the construction of charging piles.

3. Battery Supply Chain Industry

Batteries are one of the indispensable core parts of electric vehicles, battery manufacturers/suppliers, and industries related to batteries, motors, and electronic control technologies. However, in these industries, our company will also provide corresponding aluminum alloy die-casting parts, such as Battery Housing, Battery Charger Housing, AC/DC Converter Housing, etc.

4. Electric Vehicle accessories

To have an electric car, you must have a charging plug, a charging cable, and the interior of various models. These industries are the same as the charging pile and battery industries.

5. Electric Vehicle Maintenance Industry

Including the repair and maintenance of electric vehicle parts.

• The "fuel tank" of new energy vehicles-batteries: the battery is one of the main parts of electric vehicles, and the function of the battery is the only source of power for the vehicle's drive system. At low speed and starting, the battery plays the role of the main power source of the car's drive system; when accelerating at full load, it acts as an auxiliary power source; during normal driving, deceleration, and braking, it acts as storage energy.

• The key to determining power-motor: The motor has two working states, one is used as a motor, responsible for converting the electrical energy in the battery system into kinetic energy, and when it is not needed to drive the vehicle, it can also play the role of a generator Features, convert the kinetic energy of the vehicle into electric energy and store it back in the battery. The power supply provides electric energy for the driving motor of the electric vehicle. The electric vehicle motor converts the electric energy of the power supply into mechanical energy and drives the wheels and working devices through the transmission device or directly.

• The "housekeeper" of the new energy vehicles-electronic control system: The electronic control system of electric vehicles is the brain of electric vehicles, which refers to the entire vehicle control system, which integrates the functions of ECU and TCU (engine and gearbox control computer). We all know that the ECU control of traditional fuel vehicles is more complicated. The fuel injection quantity, timing phase, throttle opening of the engine, ignition, exhaust gas circulation, etc. all need to be controlled, and according to the driver’s intentions, the ECU must also interact with the gearbox. The program is calibrated in coordination to complete smooth gear changes and fully understand the driver's intentions.

Last week, we have participated in the "Die Casting Exhibition" in Dongguan, China in November 2020. This exhibition gathered the elites of our Chinese die-casting industry to share industry information and learn from each other's die-casting technology.

1. The following are some die casting products in the exhibition:

2. The exhibitors are all gathered together and are actively discussing:

3. Below are some of the automatic machines displayed in the exhibition:

Through the exhibition, we gained a lot about the knowledge and technology of the die-casting industry, learning from each other with the elites of the die-casting industry, so that our company’s technology has been improved even more, and what's more fortunate is that our products have been praised by competitors, so we will innovate more technologies and products, as far as possible to give our company more room for development.

• With the development of our company getting better and better, the discussion of our leaders will expand our company's scale. Therefore, last week, our company sent representatives to participate in the 2021 graduates of Guangxi University Winter Election Meeting, the purpose is to recruit some outstanding talents and create a better future with our company.

• As the picture shows:

• This is our company’s booth at the job fair:

• As shown in the picture, many students actively participated in the interview of our company:

• Our company actively participates in the two-way selection of new models of exchanges between enterprises and talents. Through the new model, our company cultivates more outstanding talents, not only for the development needs of our company but also for the talented people to provide a stage to realize their dreams, so that they can better display their talents and achieve their goals.

• EMP sincerely welcomes talents to join and jointly develop a new journey of win-win for enterprises and talents.

• Reasons:

①　It is caused by the side and corner of the mold, equipment, or worktable when opening the mold.

②　The castings of each operation process are stacked.

③　Improper behaviour of each process, such as throwing.

④　During operation and transfer between processes, the castings were not separated and protected, or the castings collapsed.

⑤　During each operation procedure, such as die-casting pick hooks, picking pliers, files and punches in the cleaning process.

• 5 ways of avoiding “scratches”：

①　When the casting is demoulded, be careful not to bump.

②　Obey the operating instructions, the castings are not allowed to be stacked and must be neatly placed in the workstation equipment one by one.

③　Not allowed throwing the castings during production, and must be handled carefully.

④　Placed the castings must be protected separately, and the transfer must be slow to prevent them from collapsing or falling.

⑤　Using the tools correctly. It is not allowed to hook or pinch the casting body when removing them from the moulds.

EMP treats every customer's project with a careful, scientific, and rigorous attitude, and we never allow the slightest flaw in the die-casting parts.

A. Reason:

1. Sticking mold.

2. The iron content in the aluminum alloy is less than 0.6%.

3. The ejection of the casting is skewed, or the core axis is skewed.

4. The core and wall have pressure scars.

5. The wall surface is rough.

6. The casting slope of the core and wall is too small or the inverted slope appears.

7. Paint is often not sprayed.

B. Measures:

1. Correct the mold to ensure the manufacturing slope.

2. Polish the indentation.

3. the rational design of the gating system, avoiding the metal core flow hedges, wall type, and appropriate to reduce the filling speed.

4. Modify the mold structure.

5. Polish the surface.

6. The amount of paint is thin and even, and paint cannot be missed.

7. Appropriately increase the iron content to 0.6~0.8%. Aluminum alloy die-casting parts can be manufactured into die-cast auto parts, die-cast auto engine pipe fittings, die-cast air-conditioning parts, die-cast gasoline engine cylinder heads, die-cast valve rocker arms, and die-cast valve branches.

1. There is gas in the raw material. In the production of die castings, since the main component of the gas contained in the aluminum liquid is hydrogen, the level of hydrogen content in the aluminum alloy liquid is directly related to the number of pores produced in the casting. The holes in the casting reduce the mechanical properties, corrosion resistance & airtightness of the alloy.

2. The influence of mold gating system. The gating system determines the design quality of a die-casting mold, and it is the main factor that determines the quality of the die-casting parts in later production. The runner is open in the direction of the dense side, the molten aluminum will reach the blind spot first, and when it returns, it will produce a vortex and roll-up. The quality of the left side of the casting is reduced & the airtightness is reduced.

3. Equipment performance. Air holes, shrinkage holes, and cold zones in aluminum die castings are also the air leakage of causes in aluminum die castings, and the performance of the equipment plays an important role. For products with strict requirements on airtightness, a suitable die-casting model needs to be selected.

4. Method of operation. During the die casting process, some coatings have high volatilization points & large air volume directly affects the casting porosity. The release agent is sprayed manually, and the dosage has determined by experience. If the spray volume is too large or the spraying time is too long, a large amount of gas will evaporate. Also, low mould temperature & untimely volatilization will result in large porosity.

5. Control the machining allowance. During the moulding process of die castings, the cavity has filled at the fastest speed, molten aluminium can be rapidly solidified in the mould to form a product, and holes or shrinkage will appear inside the casting. Due to the rapid solidification, the surface layer of the casting is a fine particle layer. The mechanical properties of these fine particles are very high. The production process changes for different castings, the thickness of the dense structure layer will be different.

6. Reasonably add rebates. The pinhole degree reflects the spatial distribution density of pinholes and is a factor that affects the casting airtightness. Due to the influence of small holes and oxidized inclusions in recycled materials, there are more pinholes in the castings, resulting in a higher scrap rate of single castings in production. To save energy, waste materials and runner recycling are reused in production, resulting in a decrease in the casting airtightness.

7.  Choose a reasonable pressure chamber fullness. After selecting the punch diameter and die casting machine, each casting has a different molten metal weight. If the amount of molten metal injected into the pressure chamber is insufficient (when the pressure chamber is low), the pressure chamber gas cannot remove, and turbulence will form, which is easy to participate inside. Defects such as pores and insufficient perfusion will appear at this time. Too much oxide scale in the pressure chamber will form a partition wall inside the casting, and the casting strength will reduce. Under the action of the leak test pressure, leakage is prone to occur.

According to analysis, it is difficult to solve the problem of poor air-tightness of die castings. The reason may be the comprehensive influence of various casting defects.  When dealing with poor airtightness, it is necessary to analyze the alloy properties, the process, and the mold. Then find out the main reason and take targeted measures, which can effectively improve the air-tightness of aluminum alloy die castings.

1. Zinc Alloy

Zinc alloy is an alloy based on zinc and other elements. Commonly added alloying elements include low-temperature zinc alloys such as aluminum, copper, magnesium, cadmium, lead, and titanium. Zinc alloy has a low melting point, good fluidity, and is easy to weld, braze and process plastics. Also, in the atmosphere, zinc alloys are highly corrosive and easy to recycle. Material made by melting method, die casting, or pressure processing.

• Advantages of Zinc alloy:

1.  Good casting performance. It can die-cast precision parts with complex shapes and thin walls, and the surface of the castings is smooth.

2. Various surface treatments are available. E. g: electroplating, spraying, painting, polishing, grinding, etc.

3. When melting and die-casting, it does not absorb iron, does not corrode the pressure, and does not stick to the mold.

4. It has good mechanical properties and abrasion resistance at room temperature.

5. Low melting point. Melty at 385°C, easily die-casting.

   
   

  B. Aluminum Alloy

Aluminum alloy is the most widely used non-ferrous metal structural material in the industry and used in aviation, aerospace, automobile, machinery manufacturing, shipbuilding, and chemical industries. With the rapid development of the industrial economy, the demand for aluminum alloy welded structural parts is increasing, and the weldability of aluminum alloy also study in-depth.

•  Advantages of Aluminum Alloy:

1. The density is small. The density aluminum alloy is close to 2.7g, about 1/3 of that of iron or copper.

2. Aluminum alloy has high strength. After cold working, it will increase. Heat treatment is strengthening other grades of aluminum alloy.

3. Good electrical and thermal conductivity. The electrical and thermal conductivity of aluminum is second only to silver, copper, and gold.

4. Good corrosion resistance. The aluminum surface is prone to naturally produce a dense and strength AL2O3 protective film, which can protect the substrate from corrosion. Through artificial anodic oxidation and coloring, cast aluminum alloy with good casting performance or deformed aluminum alloy with good processing plasticity can obtain.

5. Easy to process. After adding certain alloying elements, a cast aluminum alloy with good casting properties or a deformed aluminum alloy with good processing plasticity can obtain.

• The differences between zinc and aluminum alloy as below chart:

Everyone who sees here has already felt the difference between zinc alloy and aluminum alloy. Each has its advantages and disadvantages. Should choose the material suitable for your product according to the quality, technology, life, and other product requirements. EMP insists on producing according to customer needs and using the highest quality and most suitable materials.

Aluminum alloy ingot

Zinc alloy ingot

• On April 17, Jihu Automobile, a high-end brand of BAIC New Energy Automobile, announced the official launch of its second mass-produced model Alpha S. The new car positioned as a medium-to-large car with a maximum range of 708km.

• It is worth mentioning that the Polar Fox Alpha S Huawei HI version model is not only equipped with the Huawei HI solution but also the first smarts electric car equipped with the Huawei Lidar solution.

• The biggest highlight of the Huawei HI Alpha S version is that it's equipped with Huawei's autonomous driving technology. Technically speaking, it has reached a level where it can judge road conditions and drive itself throughout the process.

• Alpha S Huawei HI version will be equipped with three 96-wire automotive ranging radars, six millimeter-wave radars, 12 cameras, 13 ultrasonic radars, and Huawei chips with a computing power of up to 352 Tops.

• In addition, the HongmengOS smarts connected cockpit develop for human-computer interaction. It supports up to 24 application ecosystems such as Longlink Express, Gaode, Kugou Music, and Kuwo Music. It uses interactive applications higher than mobile phones to achieve human Machine Interaction Interaction Human-to-human interaction & vehicle interaction. To break the dilemma that it is difficult to update the car and machine application so that the application can update from time to time just like a mobile phone.

• Huawei empowers Alpha S Huawei HI version with the leading technology of Power Domain. In response to concerns about the "slow charging" of new energy vehicles, Huawei base on the accumulation of more than 30 years of power electronics technology. Provides the industry's unique AI flash charging full-stack power domain high-voltage platform solution, which can charge up to 197 kilometers in 10 minutes. Just a cup of coffee, Alpha S Huawei HI version can be full of energy. The dual-motor intelligent four-wheel drive can run into a 3-second club with a 100-kilometer acceleration. It has comparable super-running performance and enhances the user's car experience.

• The post-treatment of the heat sink housing surface refers to the filling, surge, and powder spraying of the internal anti-corrosion paint.

• Common defects are as follows:

1.  The internal anti-corrosion cannot be hung up. Because of poor pre-treatment effect or improper coating configuration, the welding area is directly exposed to water & corrosion occurs.

2. After drying, there are honeycombs or cracks on the internal anti-corrosion end. If the inner cavity is wet and full of anti-corrosion paint, water will evaporate. The raw material of water-based paint, the ratio problem, too much water/ethanol can also cause evaporation. Solvent-based internal anti-corrosion coatings increase the boiling point. If the solvent content is lower, the time in the mold cavity is shorter, which will cause the solvent to evaporate rapidly during the baking process, and honeycomb holes will appear. Thus, after filling the paint, it requires at least 1 hour and air-dried as soon as possible.

3. Many cases of heat sink housing cracks cause by local accumulation of paint that is too thick and not fully cured. The upper part solidifies, while the lower part is still evaporating the solvent, causing cracks.

• Above drawbacks, impurity ions in water infiltration/accumulation/fouling. Or the accumulation of scale inhibitors (acid or alkali) added to the water will cause faster corrosion.

• Internal anti-corrosion, no adhesion. The internal anti-corrosive resin and filler are important.  

1. With less resin, the film becomes brittle and not smooth, which will reduce the corrosion resistance.

2. The filler fineness is insufficient, and many uneven particles appear in the film. Large particles are easily washed away and cause pitting corrosion.

3. The filler grade is too low, resulting in the film thickness does not increase, the hiding power reduces, the hardness is insufficient, and the corrosion resistance being reduced.

•  The defects of the outer coating include broken wires, cracks on the exposed bottom, serious orange wires, pinholes, small cracks, etc. Under normal circumstances, the material is too poor, the pre-treatment is unqualified, and the heat sink processing technology is unqualified. Due to the long development time of powder coatings, plastic powders above the medium level will not have quality problems.

• With the rapid growth of new energy vehicles, China has ushered in the era of electric cars. According to statistics from the China Association of Automobile Manufacturers, the cumulative sales of new energy vehicles in my country last year was 1.367 million, a year-on-year increase of 10.9%. The production and sales volume of new energy vehicles ranked first in the world for five consecutive years. In the first four months of this year, the national production and sales volume of new energy vehicles exceeded 700,000, reaching 75 million and 732,000 respectively, increasing 2.6 times and 2.5 times year on year. It expects that the annual production and sales volume will reach 1.8 million vehicles this year, increasing 40% year on year.

• According to the National New Energy Vehicle Development Plan, it estimates that by 2025, the country's sales of new energy vehicles will account for 20%. By then, sales of new energy vehicles will reach about 6 million. It expects that new energy vehicles will grow at an average annual rate in the next five years. It can be more than 40%.

• In recent years, the technological level of my country's new energy automobile industry has rapidly improved, and a relatively complete industrial ecosystem and supporting environment formed. It updates at multiple levels such as master components, batteries, motors, electronic control systems, the entire industry chain layout, and the supporting layout of charging piles.

• Under the background of global green and low-carbon emission reduction in the next 30 years, fuel vehicles will gradually withdraw from the market. New energy vehicles will become the protagonist of the automotive market. At present, the annual direct economic scale of my country's automobile industry is about 10 trillion yuan. From an industry perspective, the future of the new energy automobile industry can range from parts to vehicle production to intelligent systems and charging pile systems. Measured on a trillion scale, the future market potential is blocky, and the new energy automobile industry is booming, becoming a rare emerging industry track.

• Some experts believe that China's new energy automobile industry has entered a competitive Warring States era. From traditional car manufacturers to Internet leaders, from real estate giants to mobile phone giants, all have reached out to the new energy vehicle field, hoping to share the blocky market feast of the new energy vehicle industry.

• EMP has been committed to the automotive industry for more than 20 years. With rich experience and technology in the production of auto parts. We will introduce more advanced technology and equipment to provide customers with satisfactory solutions

• It refers to neutral total carbon emissions, which are balanced by offsetting as much carbon as emissions.

For example, humans produce 10g of carbon dioxide when they breathe, while plants absorb 10g of carbon dioxide during photosynthesis. In this process, the amount of carbon emitted and the amount of carbon absorbed cancel each other out, and no produced excess carbon dioxide.

• Impact:

1. "Carbon neutrality" electrifies transportation. To achieve "carbon emission neutralization", policies have been explored to explore transportation electrification plans and policies have been formulated to ban the sale of fuel vehicles.

   
   

   In the future, transportation will electrify, and fuel vehicles will gradually replace. The utilization rate and sales volume of new energy vehicles will increase. It even promotes the development of the automobile industry to hybrid and pure electric cars and expands the business of electric vehicle manufacturers.

   
   

2. The development of automobile brands electrification. Automobile companies such as Volvo, Volkswagen, and Mercedes-Benz have all proposed electrification strategies. And stop the production of pure fuel vehicles, switch to electric, and develop in the direction of hybrid and pure electric. From last year to this year, the stock prices of many electric vehicle companies have been affected and have soared. Among them, Tesla CEO Musk was promoting to the world's richest man. From this year to the next ten years, the electrification of automobiles may become the mainstream trend.
   

   
   

3. The industrial chain that drives automobile production. When the demand for electric vehicles gradually increases, the need for manufacturers and aluminum alloys will also increase, which promotes the development of aluminum alloy die-casting plants. The formation of the industrial chain will help the economy and production development, reduce carbon emissions and protect the environment.

• In recent years, the influx of capital has driven the investment expansion of electric vehicle industry chain projects. T new energy power battery industry represented by lithium-ion batteries has undergone a structural extension. Lithium batteries are the core component of new energy vehicles, accounting for 40% of the total production costs of new energy vehicles.

• Electric compressor:

The new energy thermal management system has undergone earth-shaking changes, from traditional cabin cooling to cabin and battery cooling and heating. A wide range of cooling and heating capacity adjustments is an urgent issue for thermal management. The CO2 rotor electric compressor solves the problem of low-temperature heating.

It has the technical characteristics of high efficiency, low noise, and lightweight. And can meet the needs of high-efficiency refrigeration and low-temperature heating.

Even in a low-temperature environment of -35℃, the heating capacity is still strong. Users in cold regions no longer need to "cover a quilt" to drive. They solve the problem of rapid decay of endurance in cold conditions. Compared with traditional heat pumps, the cruising range is increased by 20%.

• Main die casting drive motor:

As the "engine" of a new energy vehicle, the motor is responsible for converting electrical energy into the battery system. The second is kinetic energy. When you don't need to drive a car, you can also use the characteristics of a generator to convert the kinetic energy of the auto into electrical energy and store it back in the battery.

• EPS motor:

EPS motors are electric power steering, mainly used in the automotive industry. The current EPS motor drive system is an important research direction in the field of automotive electrical technology and has good potential.

• Electronic water pump:

A kind of piezoelectric material as the powerplant, complete the electronic control from control to drive. And with the Electronic integration system to control the new type of water pump for liquid transmission, to realize the adjustability and accuracy of Liquid transfer.

• Electronic oil pump:

The function of the oil pump is to deliver the oil to the friction part of the engine so that the oil circulates in the lubrication circuit to ensure good lubrication of the engine. Oil pumps are mostly gear pumps, which consist of gear pump bodies.

When the engine is working, the camshaft drives the driving gear of the pump body to rotate. The gear oil flows along the inner wall of the pump from the oil inlet to the oil outlet, forming a low pressure, generating suction, and the oil in the oil tank is sucked into the oil inlet. The grease at the oil outlet accumulates more and more, the pressure increases, and the oil is pressed to the friction part to achieve forced lubrication.

1． Different sources of energy.

As can be seen from the name, electric cars use electricity, while ordinary cars use ordinary gasoline. Due to different energy sources, their use methods are also unequal. Electric vehicles mainly rely on charging, and fuel vehicles mainly rely on petroleum.

2． The waiting state is different.

While the car is waiting, ordinary vehicles still need to consume gasoline. For example, when you encounter a red light or a traffic jam, you are unlikely to turn because the waiting time at this time is uncertain. It may be a few minutes or tens of minutes, which is different for electric vehicles. The electric car is not afraid of stalling, it can stop completely, and it will not take long to start like an ordinary car. In addition, some electric vehicles have battery panels. When waiting for the auto, if there is sun, you can charge while waiting.

3． The emissions are different.

General energy vehicles burn gasoline, so the exhaust contains a lot of exhaust gas, which causes harm to air pollution. The air quality in big cities is low, mainly because cars burn too much oil and exhaust gas exceeds the natural balance. Electric vehicles have no emissions, are perfectly environmentally friendly, and will not adversely affect the environment.

• Aluminium electric vehicle motor controller (housing)

  
  

• The motor controller is the nerve centre connecting the motor and the battery, used to adjust the performance of the vehicles. It not only guarantees the basic safety and precise control of the car but also exerts sufficient power. At present, the more common forms in the industry are single motor controllers, integrated motor controllers, and integrated powertrains. Compared with micro-face logistics and special vehicles, there are more single-motor controllers. Light trucks and buses use a second all-in-one motor controller. The overall development goals are the best performance, reliability, best cost, and lightweight development.

• The motor controller is used to drive the main motor on the electric vehicle. Generally, it receives the signal of the whole vehicle controller to control the starting, running, speed regulating, and stopping of the main motor. Together with the whole vehicle controller, it is just like the brain of the electric vehicle being an important part of the electric vehicle. At present, the motor controller is increasingly integrated, including single main drive controller, three-in-one controller (integration: EHPS controller + ACM controller + DC/AC), five-in-one controller (integration: EHPS controller + ACM controller + DC/DC + PDU + dual-source EPS controller), passenger car controller (integration: main drive + DC/DC) and other controllers.

• Function: When the controller protects by over-discharge or the motor is running, a fault or malfunction may cause damage and other malfunctions. The circuit will take protective measures based on the feedback signal.

A.Improve efficiency and output 

1. The foam model used for the infiltration of aluminum alloy die castings adopts mechanical foaming. While ensuring the quality of the model, the production speed is also quite fast.

2. The dipping process of aluminum alloy dies castings simplifies the cumbersome steps of traditional crafts, such as forming the core, which is time-consuming, labour-intensive, and inefficient.

3. The aluminum alloy dies casting is immersed in a box for multiple injections until the metal solution uses up.

B.Cost savings

1. The infiltration mold used for aluminium alloy dies castings can be used for life with almost no loss, reducing or eliminating mold costs.

2. The impregnation of aluminum alloy dies castings abandons the traditional core forming process, saves labour, and reduces manufacturing costs.

3. The penetration of aluminum alloy dies castings has gradually increased the number of female workers in the foundry industry. All aspects of labour and wage costs have been reduced.

4. The sand used for the soaking of aluminium alloy die castings can be recycled, and the loss rate is 2%-5%.

5. Immerse the die-casting parts in the impregnation liquid, penetrate the loose parts inside the die-casting parts, and improve the air-tightness of the die-casting parts.

1. Production process

Incoming material selection, smelting and refining → die-casting molding → shaping and trimming → finishing → cleaning and cleaning → assembly and assembly

2. Process value

According to the structural modeling characteristics and processing conditions of the shell aluminum alloy castings, the casting pressure needs 350T. In addition, when the staff summarizes the experience of similar parts processing in the past, they will find that once the mold and process values are inappropriate. When the aluminum alloy parts are open, the liquid metal filling time will be too short. The timely volatilization of a large amount of gas in the closed cavity is blocked and blocked, resulting in a series of quality defects such as large dense pores and oxidized impurities in the finished product, which reduces the qualification casting rate. Therefore, precise positioning requires during use, and the processing needs controlling within 0.5mm. Improve the compression resistance of the parts, shorten the machining time, and enhance the inherent quality of the production of aluminum alloy parts for the shell.

3. the model scheme

In the production and processing process of aluminum alloy parts, it is necessary to conform to the wave of social development, realize information innovation, introduce corresponding information technology, improve work content, and increase work efficiency. The staff repeatedly compared and polished, and when filling with liquid sulfur, the model with a large flow channel flow will select as the actual part processing mold. It can improve the hidden defects inside the castings and increase the yield rate.

4. Melting temperature

According to the actual weight of the finished product, a 350T high-quality cold die-casting machine can use as the main body for die-casting of parts. Real-time temperature control is necessary. In the case of semi-finished products, they should maintain within the range of 640°C to 20°C. In the process of a liquid metal filling, to keep the pressure stable, it should be emphasized to prevent errors such as splashing and laminar turbulence, and the pressure rise rate is limited to 1.5kP/s. It helps to avoid repeated oxidation of slag inclusions and frequent scouring of the mud core by molten metal.

5. Alloy liquid purification

To improve product quality, refining is carried out when the semi-finished alloy is completed. At the same time, install a fibre filter at the riser nozzle and a ceramic filter at the level gate of the gold tail liquid. It is also necessary to add a filter screen made of double-layer fibres to the residue of the horizontal gate and the slit to achieve three-time fine filtration.

6. Defect detection

In the quality control of aluminum alloy production and processing, X-rays must be used to complete flaw detection tasks and control the internal quality of parts. When shell parts are processed in batches, visual examination and X-ray inspection will lead to labour and capital shortages. Therefore, the staff can use CAE modern technology to analyze and monitor the entire production process of the parts and find out the hidden quality problems of the components in the casting process in time. The quality problems of integral castings are limited to semi-finished blanks and completely concentrated processing stages.

• Methods to reduce porosity in aluminum die-casting products

1. Ensure the refining and degassing quality of aluminum alloy smelting, and select a good refining agent and degassing agent to reduce the gas content in the aluminum water. Remove the scum, bubbles, and other oxides on the liquid surface in time to prevent the gas from entering the die-casting parts again.

   
   

2. Choose a great release agent. The selected release agent should not generate gas during the die-casting process and has good release performance.

   
   

3. Ensure that the exhaust of the mold is unobstructed, and ensure that the gas in the mold is completely exhausted, especially the exhaust channel for the final polymerization of the aluminum liquid.

   
   

4. Adjust the die-casting parameters, and the filling speed should not be too fast to prevent air entrainment.

   
   

5. Pay attention to the use of core pulling and cooling in product design and mold design to minimize the shortcomings of excessive wall differences.

   
   

6. The pores that often appear in the fixed position should be improved from the mold and design.

• Features

  1. Small heat-affected zone

Due to the millisecond pulse discharge time, the precise energy control (small solder joint 1.6-2.0mm) does not affect the area outside the welding area. Achieve a cold welding effect without thermal deformation of the base material.

  2. Thin welding thickness

The controllable melting temperature is 0.1-0.8mm, so aluminum alloy thin plates below 0.2mm can be welded.

  3. High degree of integration

This machine belongs to metallurgical bonding, and the bonding strength after welding is high. It can adapt to various processing forms without falling off.

  4. High repair welding efficiency

Automatic wire feeding is adopted. The diameter welding wire is 0.8-1.2mm & the welding spot diameter is 1.6-2.0mm. Instant heating, short solder joint formation time.

• Scope of application

1. Pressure vessels have welds or pores after weldings, such as arresters, expanders, and other ships.

   
   

2. Such as cylinder head, suction pipe, shell, communication equipment shell.

   
   

3. Repair of wear and tear of aluminum alloy molds, such as the lines on aluminum alloy shoe molds, repair of signs of wear, etc.

   
   

4. Repair the defects of various aluminum alloy materials.

• Al 380 is the most widely used type of aluminum alloy. It can achieve the best combination of die-casting process and product performance. And it has a wide range of applications, such as lawnmower shells, electronic equipment bases, auto parts brackets, automobile transmission system shells, household appliances, hand tools, power tools, etc.

Automobile transmission system housing              

Car parts bracket

• Application of similar materials

1. To ensure the refining and degassing quality of aluminum alloy smelting, select good refining agents and degassing agents. It reduces the gas content in the aluminum water, removes scum, foam, and other oxides on the liquid surface in time, and prevents the gas from being brought into the die-casting again.

   
   

2. Choose a good release agent. The selected release agent should not generate gas during the die-casting process and has good release performance.

   
   

3. Ensure that the mold exhaust is smooth and not blocked. Smooth exhaust to ensure that the gas in the mold is completely exhausted, especially the exhaust channel where the aluminum liquid is final aggregation must be unobstructed.

   
   

4. Adjust the die-casting parameters, and the filling speed should not be too fast to prevent air entrainment.

   
   

5. Pay attention to the use of core-pulling cooling in product design and mold design to minimize the shortcomings of excessive wall differences.

   
   

6. The pores that often appear in the fixed position should be improved from the mold and design.

• The uneven wall thickness of the casting is prone to defects such as shrinkage. The solution is to increase the feed channel of the casting (increase the fillet of the casting) when the thickness changes to avoid the vertical shape in the casting.

  
  

• Another method is to increase the temperature difference during the solidification of the casting. This not only guarantees the bottom-up solidification sequence of the casting but also reduces shrinkage.

  
  

• The other is to reduce the amount of gas discharged from the casting cavity. If the amount of gas discharged from the cavity is too large, the casting will have many cavities.

1. The chemical composition inspection, test methods, inspection standards and re-inspection of aluminum die-casting molds must meet the standards of GB/T15115. The chemical composition of the sample product can be die-cast, which meets the requirements of GB/T15115. Mechanical properties The mechanical properties, test methods, test times, and test specifications must meet the requisition of GB/T15115.

   
   

2. For samples used in aluminum die casting molds, the cut parts' size and style need to be carefully confirmed.

   
   

3. The geometric shape inspection of die-casting parts can be carried out by sampling in a wide range, or by the standards of GB2828 and GB2829. . Test results must meet specifications.

   
   

4. The appearance inspection of aluminum die castings must be inspected item by item, and the results must meet the standard requirements.

   
   

5. The surface roughness of aluminum die-casting mold should implement according to GB/T6060.1 standard.

1. The anodizing temperature of die-cast alumina colouring is generally below 23 °C. If the temperature is too high, the consumption of cold sealant will be large, and the surface will turn green.
   

   
   

2. When die-casting aluminum is anodizing and coloured, take out the falling aluminum in time. Otherwise, it will accelerate the increase of pH and fluorine consumption.

   
   

   
   

3. It needs to be cleaned in time after anodizing because staying in the oxidation tank will affect the sealing. Otherwise, it will cause pollution and increase the fluorine consumption of the sealed tank.

   
   

   
   

4. After the closed fluoride tank is regular with ammonium fluoride, it should fall once to clear the bottom. The hydrofluoric acid-adjusted fluorine sealed tank should be produced 5-10 minutes after addition, preferably in the form of a 10% dilute solution.

   
   

5. To improve the sealing quality and speed up the drying speed, after cold sealing, it is recommended to wash with hot water at 55±5℃ for 10 to 15 minutes, also known as cold sealing post-treatment.

• To achieve ultra-high data transmission rate and extremely low network delay, on the one hand, the signal transmission power consumption of 5G AUU (RRU and antenna integrated unit) increases significantly; Power consumption will also increase significantly. According to the data of the tower company, the power consumption of a 5G single station is 2.5-3.5 times that of 4G. From the perspective of thermal design, the heat generation of the base station increases, and the difficulty of temperature control increases sharply. To solve the heat dissipation problem of 5G base stations, it is necessary to develop new high-conductivity die-casting materials.
  

• Al-Si casting alloys are often used as die-casting aluminum alloy materials. The main problem with this type of alloy is that the thermal conductivity is low, but it does not meet the design requirements. Taking the commonly used ADC12 alloy as an example, the thermal conductivity of aluminum is about 96W/(m·K), while the thermal conductivity of aluminum profile-6063 is 200W/(m·K). Therefore, it is a problem to be solved to study the factors affecting the thermal conductivity of die-casting aluminum alloys and try to improve its thermal conductivity.

• Due to the purifying effect of boron on aluminum parts, three aluminum alloy materials with high thermal conductivity have been developed. It not only ensures high thermal conductivity but also improves the casting performance of the alloy. High thermal conductivity aluminum alloys have been widely used in base station radiators, photovoltaic inverter radiators, 5G optical modules, LED lights, and other fields.

Please see the table below:

1. The integration of die-casting contributes to the light-weight of automobiles

According to the information released by the State Ministry of Industry and Information Technology, light-weighting as one of the key technologies for energy saving in automobiles has significant energy-saving effects. The key components are developed in the direction of thin walls, high performance, and large size, which can effectively contribute to the light-weighting of automobiles.

2. Parts: Aluminum die-casting parts are developing toward large-scale and integrated development

With the further improvement of the application technology of aluminum alloy materials, cars are driven by the need for lightweight design. The key components aluminum battery charger, aluminum transmission housing, aluminum battery housing, etc. Are developing in the direction of high pressure die casting, large-scale, and integration.

3. The integrated die-casting technology significantly improves the material recycling rate

Under the traditional manufacturing process, the materials used in automotive product parts are complex and diverse, and the material recycling rate is low. The integrated die-casting only uses one material, so, when recycling, the scrap can be melted directly to make other products, ensuring the recycling rate of materials in the manufacturing process of automotive parts.

Hard anodizing is a kind of processing service. The surface of products treated by hard oxidation is more beautiful. With more and more hard anodizing processing of aluminum precision parts, what are the cleaning methods for aluminum precision parts after hard anodizing?

No. 1 Cleaning Method for aluminum die casting parts after hard anodizing：

After degreasing aluminum surface treatment water washing, aluminum anodizing coloring is intended to prevent the grease of the failed products and affect the stability of the plating solution.

Aluminum precision hard anodizing, to wash off the residual liquid film alkali corrosion on the surface of aluminum concentrated alkali corrosion tank, water washing alkali corrosion needs to be cleaned at least three times. Due to the difficulty of cleaning, it is recommended that sink water be used to reduce the time of change and ensure a certain temperature and alkalinity, which is conducive to cleaning products.  

No. 2 Cleaning Method for aluminum die casting parts after hard anodizing：

Electropolishing after chemical washing: in the two water cleaning lines, aluminum hard anodizing stain washes viscous liquid drugs appear on the cast aluminum surface, which indicates that the first tank should ensure a certain temperature so that the second tank can be used to clean the product with circulating water so that the effect will be better.

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Aluminum Automotive Components Overview

Aluminum is a key item used in the production of automotive aluminum parts and assemblies. EMP Die Casting is a leading provider of custom aluminum die cast components for the automotive aluminum parts market. We specialize in the production of new energy vehicle charger enclosures, combustion engine oil pans, bed plates, oil circuit breakers, front and rear automotive wiper motor frames, brackets, stop-start device gearbox enclosures for combustion engines, half disk&medium disk, etc.

Automotive Aluminum Parts Details

Oil pan: Located in the lower part of the engine, detachable, and seals the oil shaft box and provides the outer casing of the oil sump.

Bracket: The automobile wiper motor bracket serves as the installation structure of the wiper motor assembly. Along with installation accuracy, the stiffness performance of the bracket mounting point will directly affect the performance of the wiper system.

Stop-start device gearbox enclosures for automatic vehicles: The gearbox is a mechanical device for increasing/decreasing torque by deceleration/increase. It consists of two or more gears, one of which is driven by a motor. The output speed of the gearbox is inversely proportional to the gear. Gearboxes are generally preferred in constant speed applications, such as conveyors and cranes, which can provide increased torque.

EMP automotive parts manufacturer, as one of has been developing automotive component enclosures for many years. As one of automobile parts manufacturing companies, not only the parts mentioned above, but also a large number of aluminum die castings are under development. At EMP, we stand ready to provide you with the custom automotive parts you need.

Electric Vehicle Parts Overview

Battery Electric Vehicles (BEVs) also known as New Energy Vehicles (NEVs) are made up of three main segments: the traction motor, the battery pack, and the electrical control units. EMP Die Casting is a electric car parts manufacturer, and we specializes in not only the production of the larger BEV/NEV parts, but also the smaller sub-assemblies that make up each segment of the vehicle. We product key products and components such as the motor housing, battery case, DC-AC converter enclosure, battery control ECU enclosure, on-board charger, HV/EV ECU enclosure, and others. EMP as one of leading aluminium die casting manufacturers in China, is consistently researching and developing new ways to produce and improve NEV parts to make our technology smarter, more powerful and our product lighter and more efficient.

Electric Vehicle Parts Details

Motor Housing: The purpose of building new energy vehicles is to reduce energy and emissions. The motor housing is an important part of a new energy vehicle motor. Therefore, to both reduce weight and increase cooling, we make use of custom aluminum alloys to make a lighter, more energy efficient motor enclosure. 

These aluminum alloy enclosures not only reduce the weight of the vehicle, but they also make the vehicle more efficient by reducing the number of cooling componetry needed for the motor to operate at its best level. Our unique alloy motor cases improve the heat dissipation effect of the motor, are watertight for liquid cooling applications, and are strong enough to feature as a structural electric vehicle components. 

Battery case: Battery case is one of the most important components in new energy vehicles. The best NEVs make use of aluminum alloy for the battery case structures as key components that offer security for their battery payloads, but also structural rigidity for the vehicles. Our EV battery box has high-temperature resistance, corrosion resistance, high electrical conductivity, and good heat transfer performance. Large scale battery case castings are an exciting area for die cast aluminum casting technology.

DC-AC Converter: DC-AC Converter plays an important role in the power steering system and composite power system. For example, it can provide power to auxiliary equipment and stabilize the voltage. Our range of DC-AC Converter enclosures easily integrate into a highly-flexible architecture to deliver a unique, feature-rich set of functions and are well-matched to satisfy the electrification needs of our automotive manufacturer partners. 

As we all know, Engine is the heart of the car and it plays a grate influence on mechanical machine.Engine is an energy conversion institution,upcoming gasoline or gas heat,through the gas cylinder in seal burning,to push piston expenditure then turns the energy into mechanical energy,which is the most basic principle of engine.And the body is the framework of the engine and the installation foundation of the engine's institutions and systems. All the main parts and accessories of the engine are installed inside and outside the body and bear various loads. Therefore, the body must have enough strength and stiffness. The block is mainly composed of cylinder block, cylinder liner, cylinder head and cylinder gasket.

For example,the cylinder head is mounted on the car cylinder block to seal the cylinder from the upper part and form a combustion chamber. It often contacts with high temperature and high pressure gas, so it bears a lot of heat load and mechanical load. There is a cooling water jacket in the cylinder head of a water-cooled engine. The cooling water holes at the lower end of the cylinder head are connected with the cooling water holes of the cylinder body. Use circulating water to cool high temperature parts such as combustion chamber.Cylinder head is usually cast with gray cast iron or alloy cast iron. But as aluminum alloy has good thermal conductivity and is conducive to improving compression ratio. Therefore, in recent years, more and more aluminum alloy cylinder head has been used.

Regarding for the car engine parts, in order to effectively reduce the weight of the whole vehicle, 1.4L gasoline engine uses aluminum alloy cylinder block, which has achieved very obvious lightweight effect. And using aluminum material and plastic intake pipe processed by special technology instead of traditional metal intake pipe can not only achieve lightweight effect, but also effectively reduce the resistance of intake pipe wall, improve intake efficiency and increase engine power.

Overview of Water Pump Housing

There is a multiple cooling circulation pipe connected to the radiator in the front of the automobile, which constitutes a large water circulation system in the cylinder of the automobile motor. Automobile water pump will drive the coolant from the water tank to dissipate heat from the motor continuously. For the new energy vehicle rising in the future, the automobile water cooling system is also an essential role. EMP is one of water pump housing suppliers, provide high quality pool pump housing cover for sale.

Application of Water Pump Housing

• Petrol vehicle water pump housing

• New energy vehicle water pump housing

The specification of Water Pump Housing

1.Overview of auto starter parts

What is auto starter?Engine starting needs external support, the car starter is playing this role. Generally speaking, the starter use three parts to realize the whole starting process. The DC motor introduces the current from the battery and causes the driving gear of the starter to produce mechanical movement. The driving mechanism meshes the driving gear into the gear ring of the flying wheel and can automatically detach after the engine starts. The opening and closing of the starter circuit is controlled by an electromagnetic switch.Among them, the motor is the main internal part of the starter.

The starter is the core part of the starting system. The starter consists of three parts:DC series motor, transmission mechanism and control device in which there contain aluminum alloy parts of end cover, casing, and one-way clutch. Why there needs aluminum alloy part in a starter?Generally speacking, aluminum alloy is lighter and has stronger heat dissipation potential than any other material.

2.Application of  auto starter parts

• Ordinary starter

• Pemanent magnet starter motor

• Direct control starter

• Electromagnetic control starter

• Forced mesh starter

• Armature changed type starter

• Sliding armature starter

• Pre-engaged drive starter

3.The specification of auto starter parts    

1.Overview of Liquid-Cooled AC/DC Battery Charger Case

Our liquid-cooled ac/dc battery charger case is made of aluminum alloy. In general, aluminum alloy is lighter and has stronger heat dissipation potential than any other material. For example, a battery must to be kept within the limits of space and weight, we want a battery to achieve more power storage, optimizing the temperature control management systems to ensure the charging speed and heat dissipation of the battery and the overall structure optimization can ensure the collision safety. In order to ensure the safety, life and charge-discharge efficiency of a battery, it should be used in the appropriate temperature range as far as possible. Both of overheating and cooling will have a great impact on a battery. Therefore, liquid-cooled battery has a set of liquid-cooled temperature management system, which relies on the constant temperature characteristics of the liquid and is controlled by the software of the liquid-cooled system to achieve a more stable battery environment. Meanwhile, Why choose aluminum alloy to be the material of liquid-cooled ac/dc battery charger case? Not only aluminum battery charger case can reduce the weight of the car, but also improve the heat dissipation effect of the battery. Eventually aluminum battery case can greatly improve the battery working efficiency and safety, prolong the battery life.

2.Advantages of Liquid-Cooled AC/DC battery charger Case

We choose all-in-one aluminum alloy die-casting case which interior is filled with high thermal conductivity sealant so that it has excellent performance of seismic heat dissipation and waterproofing, ensuring it can operate in various harsh environments for a long time.

3.Application of Liquid-Cooled AC/DC Battery Charger Case

• Electronic communications

• Transportation

• Machinery and equipment

  
  

4.Parameter of 3kW Liquid-Cooled EV Battery Charger(112-225VDC)

Product Details of Electric Vehicle AC-DC/DC-DC Converters (Housing):

1. Specification: Custom-made

2. Service: OEM/ODM Service

3. Material: Aluminum alloy

4. Application: Automobile,Truck,etc. /EV Battery Housing

5. Die Casting Machine Type: Cold Chamber Die Casting Machine

6. Quality Control System: IATF16949, ISO9001:2015

7. Apllied Software: PRO/E, Auto CAD, Solid Works,IGS,UG, CAD/CAM/CAE

8. Surface Treatment: Sandblasting, Deburring, Sanding, CNC Machining, Powder Coating

The die casting includes high pressure die casting(HPDC), low pressure dies casting(LPDC), Squeeze casting, gravity(GDC), an EMP is specialized in high pressure die casting, which is most commonly used for automotive, telecommunication, industrial etc.

The die-casting machine is generally divided into cold chamber die-casting machines and hot-chamber die-casting machines.

The cold chamber die-casting machine is divided into the horizontal die-casting machine and vertical die-casting machine according to its chamber structure and layout.

Below is the flow chart for the high pressure die casting process:raw material-melting-die casting-dating-deburring-trimming-shot blasting-CNC machining-leak test-cleaning-full inspection-packing-delivery

Die Casting Comparison

1. Process characteristics comparison

2. Mechanical Properties Comparison

The spectrometer is used to detect the composition of materials, and the computerized automatic display numerical instrument displays and analyzes to determine what kind of elements are contained in the article.

Tooling Design Overview

New technology is breaking through constantly, driven by innovative thinking. The die casting tool design team carries out new product development through professional 3D model design as well as mold flow analysis and validation to assure customers with satisfactory products.

Mold workshop is equipped with a group of professional mold design&manufacturing engineers who are proficient at computer software such as 2D/3D to assist mold design, manufacturing machines which includes CNC machining centers, EDM, WEDM, universal milling machines, friction welding equipment, etc.

Die Casting Design for Manufacturing

Optimizing die casting process is an important step to improve efficiency and optimize die casting design. All types of die casting are used for production, so it is very important to consider the production process in the design process. Pursue the efficiency of manufacturing and reduce secondary operations, which is called "Design for manufacturing" to minimize costs before the project is put into operation, in order to prevent the reduction of efficiency.

Tooling Design Process

EMP has advanced engineering and works cooperatively with customers with well-designs for cost-effective fabrication.

At the beginning, to meet customer’s requirements, we will communicate with the customers to discuss more details per drawings and gather their needs. Then we use tools such as FEA,  mold flow simulation to clarify and identify critical open issues that could be resolved to make sure producing the part successfully.

In addition, some prototyping options also support our product development and casting part design process. As one of the top 10 aluminium die casting manufacturers in China, EMP, with die casting mold and tools factory, can provide rapid prototypes within 20 to 35days and HPDC components – all with engineering support to see results and recommend if necessary changes.

• Advanced Product Quality Planning Process

• Product Design in CAD/CAM, Pro/Engineer, CATIA, or Nx

• Rapid Prototyping

• Mold Flow Analysis

• Die Design for Die Casting Tools

• Die Casting Tooling Acquisition & Technical Review

EMP Die Casting was established in 2004.

We are a worldwide leading manufacturer of precision die cast aluminum parts.

Confirm the size of the mold core and the mold base according to the product size, and reasonably distribute the ejection system, injection system and overflow system of the mold.

The design of the runner system is based on the structure and special characteristics of the product.

Quantity: 3 sets

EV battery case, also known as EV battery box, is one of the most important components in new energy vehicles. The best NEVs make use of aluminum alloy for the battery case structures as key components that offer security for their battery payloads, but also structural rigidity for the vehicles. Our battery case has high-temperature resistance, corrosion resistance, high electrical conductivity, and good heat transfer performance. Large scale battery case castings are an exciting area for die cast aluminum casting technology.

EV battery box overview

The main purpose of the battery shell of an electric vehicle is to accommodate and protect the battery. They come in different shapes and sizes, and aluminum and steel are the traditional materials for battery housings. The main obstacle to the large-scale adoption of electric vehicles is the fear that they will not be able to drive far enough on a single charge. Composite materials can provide an improved alternative to significantly improve the performance of electric vehicles. In order to alleviate this problem, it is necessary to provide qualified cars, and the parts that make up them must also have these qualities.

Advantages of EV battery case

Lose weight. The main driving force for choosing composite materials is that if the shell is made of 100% composite materials instead of aluminum, weight savings of up to 40% can be achieved, which will play an important role in the large-scale adoption of electric vehicles. 

Reduce noise. Noise is the result of acoustic propagation of vibration or noise in the cabin. 

Although not obvious in other ways, it is important in terms of commerciality and driving experience. 

Security issues. The strength and stiffness of the composite battery shell exceeds that of aluminum or steel and can be designed as part of the body structure to protect not only the battery but also the passengers. 

Pultrusion. Mass production is essential to reduce overall costs. 

Continuous manufacturing methods can be used to produce battery box components for electric vehicles, and Pultrusion process can be used to produce stronger but lighter products.

Commonly used custom brackets are custom aluminium mounting brackets, automobile generator brackets, engine brackets, and seat brackets.

Overview of Telecommunication Cover

The Communication Cavity is composed of resonator cavity,tuning screw and so on. Compared with other filters, the Communication Cavity is a microwave filter with a resonant cavity structure. A cavity can be equivalent to inductance and parallel capacitance, thus forming a resonance level and realizing the microwave filtering function. It has a firm structure, stable and reliable performance, small size, moderate Q value, far parasitic high-end passband and good heat dissipation performance, being used for larger power and frequency to filter out strong out-of-band interference signals. In general, it is better than other microwave filters.

Application of Telecommunication Cover

• Communication base station,automobile,electronic

The Specification of Telecommunication Cover

  With the development of industries such as automobiles and motorcycles, and the realization of requirements for improving the quality of die castings, saving energy consumption and reducing pollution. The application range of non-ferrous metal alloy die castings, especially light alloy (aluminum and magnesium alloy) die castings is expanding rapidly. The information shows that the replacement of steel castings with aluminum alloy and magnesium alloy castings in industrially developed countries is becoming an important development trend. At present, die casting has become one of the more widely used processes in the forming process of aluminum alloys for automobiles, accounting for 49% of various automobile forming processes.

  At present, there are about 3,000 non-ferrous metal die-casting enterprises in China, and the average annual increase rate of die-casting output is 12.58%, of which aluminum alloy die-castings account for more than 3/4 of all die-castings. The market capacity of China's automotive aluminum alloy die-casting parts is about 84 billion in 2018. The market capacity in the next 2-3 years is expected to exceed 100 billion yuan and maintain a high single-digit growth rate every year.

  With the improvement of technical level and product development capabilities, the types and application fields of aluminum alloy die-casting products are continuously expanding, from automobiles to communications, medical equipment, machinery, and artificial intelligence and other industries.

  Since the die-casting aluminum alloy was put into commercial production in 1914, with the development of the automotive industry and the invention of the cold chamber die-casting machine, its alloy types have been rapidly developed. Such as the die-casting aluminum alloy Japanese standard ADC12, ADC10, American standard A380, A360, EU ENAC43400, ENAC44300, German standard ALSi9Cu3, etc., are the most commonly used aluminum alloys for the die-casting factory.

  EMP's products are mainly composed of small and medium-sized parts, which have a wide range of products and many types. With the increase of orders and the expansion of the market size, the EMP team has achieved a good annual output value of 250 million yuan in 2019. The continuous development of the market and the long-term cooperation of customers have enabled EMP to better grasp the industry trends and product development directions and strive to create new glories.

IATF 16949(VDA6.3) certified factory,  15% of total staff are QC members who monitor the entire manufacturing process.

Part is the most basic unit, component is composed of parts, if it can move, it is a mechanism. Generally speaking, parts make up components, components make up mechanism, and mechanism makes up machine. Components can also be parts, such as large box parts, also known as components. Generally, weldments shall be treated as components.

Definition of aluminum die casting parts

Aluminum alloy die casting is a kind of pressure casting part, which uses the die casting mechanical die casting machine to install the casting mould, and pours the heated liquid aluminum alloy into the feed port of the die casting machine. The aluminum alloy parts with limited shape and size of the die are cast by the die casting machine. Such parts are usually called aluminum alloy die castings.

Advantages of aluminum die casting parts

Because the metal aluminum alloy has good fluidity and plasticity.Aluminum alloy die castings can not only make a variety of complex shapes, but also have high precision and finish.The mechanical processing of castings and the casting allowance of metal aluminum alloy are reduced, which not only saves electric power and metal materials, but also greatly saves labor costs.Aluminum alloy has excellent thermal conductivity, low specific gravity and high processability.

Applications of aluminum die casting parts

Aluminum alloy die castings are widely used in automobile manufacturing, internal combustion engine production, motorcycle manufacturing, motor manufacturing, oil pump manufacturing, transmission machinery manufacturing, precision instruments, landscaping, power construction, architectural decoration and other industries.

Aluminum alloy die-casting parts can be made into aluminum die-casting automobile parts, aluminum die-casting automobile engine fittings, aluminum die-casting engine cylinder, aluminum die-casting gasoline engine cylinder head, aluminum die-casting valve support, aluminum die-casting power accessories and other parts.

Recycling aluminum die casting parts

There is little difference in the function of primary and secondary recycled aluminum die-casting. Secondary aluminum alloy is made of pure aluminum mixed with magnesium, iron, copper and other materials. Due to cost, it is rarely used in pure aluminum casting. More than 95% of aluminum castings made in North America are made from recycled aluminum after consumption. The ease of use of aluminum alloy in die casting and its lighter weight and durability make it the first choice for designers in almost all industries, for which secondary aluminum needs only 5% of energy to be produced. Most of the energy consumption of aluminum die casting is used to heat and remelt the metal in the manufacturing process.

Overview of Oil Pump Housing

The influence of automobile oil pump is to suck the gasoline out of the tank, through the pipeline and the gasoline filter pressure to the carburetor float room, so that the vehicle motor has enough power to start,so as to start the vehicle. Because of the automobile oil pump housing, the tank can be placed at away from the back of the car, below the motor.

Application of Oil Pump Housing

• Petrol vehicle oil pump housing

The Specification of Oil Pump Housing

1.Overview of Cylinder Head Cover

There are three types of cylinder heads include flathead, overhead valve and overhead camshaft cylinder heads, each of which can be made of cast-iron or aluminum material, depending upon the specific system in which they are being used in. Our engine cylinder head cover is made of aluminum alloy. In general, aluminum alloy is lighter and has stronger heat dissipation potential than any other material. Meanwhile, Why choose aluminum alloy to be the material of cylinder head valve cover? Not only aluminum cylinder head cover can reduce the weight of the car, but also improve the heat dissipation effect of the engine.Cylinder head covers serve to seal off the cylinder head space from the outside of the engine. As a result of operation of the internal combustion engine, blow-by gases from the combustion process and oil droplets from the lubricant system of the engine are present inside the cylinder head.

A cylinder head is usually located on the top of the engine block. It serves as a housing for components such as the intake and exhaust valves, springs and lifters and the combustion chamber.

2.Advantages of Cylinder Head Cover

It conveys air and gasoline to the combustion chamber and serves as a cover for the cylinders. The main advantage of the cylinder head is to help the head gasket seal the cylinders properly so that they are able to build enough compression for engine operation.

3.Application of Cylinder Head Cover

• Single acting cylinder

• double-acting cylinder

• Diaphragm cylinder

• Impact  cylinder

• Rotary pneumatic cylinder

• Gas-liquid damping cylinder

• Step into the cylinder

4.The specification of Cylinder Head Cover

The motor controller controls the motor to work according to the set direction, speed, angle and response time through the active operation of the integrated circuit.

In an electric vehicle, the function of the motor controller is to convert the electric energy stored in the power battery into the electric energy required to drive the motor according to the command of the gear position, the throttle, the brake, etc, to control the starting operation, the advance and retreat speed, and the climbing of the electric vehicle. The driving state such as the strength, or help the electric vehicle to brake, and store some of the braking energy into the power battery.

The motor control system determines whether the electric vehicle can operate safely and reliably, and is a core component of the electric vehicle control system.

Electric vehicle battery charger

In terms of control safety technology, the three-layer safety monitoring technology of the whole vehicle control system for electric vehicles was developed, and the working parameters related to vehicle safety were monitored and processed from the functional level, the software level and the hardware level,and the large-scale operation of the electric vehicle was solved.Security monitoring issues.

The controller aluminum shell has high specific strength, specific modulus, fracture toughness, fatigue strength and corrosion resistance. Because the aluminum alloy material has low density and is non-magnetic, the alloy phase is stable at low temperatures.

The aluminum shell of the electric car battery parts will be treated by hot and cold processes, and the aluminum shell of the battery thus produced will have strong corrosion resistance. The controller of the aluminum housing is thus safer.

This kind of shell also has good ductility and can be made into a light alloy with many metal elements. Its chemical properties are stable, non-magnetic, and can be recycled. It is a benign and recyclable metal material.

The aluminum shell is also small in density and light in weight compared to other metals, so it can be said that the aluminum shell is a good partner for the new energy controller.

1.Overview of electric drive motor housing

In new energy vehicles, the electric drive motor is one of the three core components of new energy vehicles. It is the main executive structure in the operation of new energy vehicles. Its function is to convert the electrical energy of the power source into mechanical energy, through the transmission or directly drive the vehicle, playing an important role in new energy cars, buses, trucks, etc.

2. Application of electric drive motor housing

1. Water-cooled permanent magnet synchronous motor

2. Water-cooled AC motor

3. Water-cooled switch reluctance motor

4. Water-cooled DC motor

3.The specification of electric drive motor aluminum housing

1.Overview of Electric Vehicle Motor Controller

The motor controller is used to drive the main motor on the electric vehicle. Generally, it receives the signal of the whole vehicle controller to control the starting, running, speed regulating and stopping of the main motor. Together with the whole vehicle controller, it is just like the brain of the electric vehicle being an important part of the electric vehicle. At present, the motor controller is increasingly integrated, including single main drive controller, three-in-one controller (integration: EHPS controller + ACM controller + DC/AC), five-in-one controller (integration: EHPS controller + ACM controller + DC/DC + PDU + dual source EPS controller), passenger car controller (integration: main drive + DC/DC) and other controllers.

3. Application of Electric Vehicle Motor Controller

1. three-in-one controller

2. five-in-one controller

3. the vehicle controller

4.The specification of Electric Vehicle Motor Controller

The tooling room is also the process equipment room, and various tools used in the manufacturing process, such as tools, fixtures, molds, measuring tools, inspection tools, auxiliary tools, bench tools, station tools, etc.

In engineering and manufacturing, toolroom activity is everything related to tool-and-die facilities in contrast to production line activity.

Our company features a 50,000m² manufacturing plant, and 500 experienced engineers & support staff. 

With its high precision, high flexibility and excellent digitization ability, the coordinate measuring machine has become an important means for the design, development, processing and quality assurance of modern manufacturing, especially the mold industry.

Coordinate measuring machine can provide quality assurance for the mold industry, is the best choice for measurement and inspection of mold manufacturer.

The combination of a CMM probe and a CMM with different structural forms can quickly and accurately obtain the 3D data and geometric features of the part’s surface, which is particularly useful for mold design, sample replication, and repair of damaged mold.

Quantity: 1 Set

The design of the overflow material system is based on the structure and special characteristics of the product.

Mechanical parts are the basic components of machinery, which are the indivisible parts of machinery and machine. As a key part of the machinery, the quality of mechanical parts plays a very important role in the normal operation of machinery, so it is very important to choose high-quality mechanical parts. EMP Tech is a professional machinery parts manufacturer, offering high-quality machinery engine parts and attractive prices at the same time.

Quantity: 8 sets

The Electric Vehicle Battery Charger Housing has the prospect of being lightweight. The overall application cost of the aluminum alloy battery case is low, its performance meets the requirements, and the circulation channel of the water-cooled battery can be integrated. The power battery case is made of aluminum, which is easy to form, high temperature corrosion resistance, good heat transfer and electrical conductivity.

Electric Vehicle Battery Housing uses aluminum alloy as raw material, which has high specific strength, specific modulus, fracture toughness, fatigue strength and corrosion resistance stability. Because aluminum alloy material has low density, non-magnetic, stable alloy phase at low temperature, low specific resistance in magnetic field, good air tightness, and rapid attenuation of induction radiation energy, it is widely used in aviation, aerospace, high-speed train, machinery engine parts, Marine, chemical industry.

Aluminum alloy has always been the material of choice for Communication Cavity. Because its features of low density, high mechanical strength, good shock absorption performance, excellent casting performance, easy plating, spray coating, good thermal conductivity, corrosion resistance and oxidation resistance.

Aluminum die casting part can be used in wiper systems, engine systems, filter systems, air conditioning systems, precision compressor parts, shock absorption systems, braking systems, ABS systems, rearview mirror systems, power steering control systems, motors for fuel vehicles End caps, pump housing, and more.

（1）Shape and structure requirements of custom aluminium die casting:

a. Eliminate the internal side concave;

b. Avoid or reduce the core pulling part;

c. The reasonable die-casting structure can not only simplify the die casting structure, reduce the manufacturing cost, but also improve the casting quality,

（2）Wall thickness requirements of custom aluminium die casting design:

The wall thickness of die casting is a special factor in the process of die casting. The wall thickness is closely related to the whole process specification, such as the calculation of filling time, the selection of internal gate speed, the calculation of solidification time, the analysis of mould temperature gradient, the effect of pressure (final specific pressure), the length of mould retention time, the height of casting ejection temperature and operation efficiency.

（3）Requirements for design reinforcement of custom aluminium die casting:

The function of the rib is to improve the strength and rigidity of the parts after the wall thickness is thinner, to prevent the reduction of the shrinkage deformation of the custom aluminium die casting. And avoid deformation when the workpiece is ejected from the mould. The thickness of the custom aluminium die casting bar should be less than the thickness of the wall, generally 2 / 3 ~ 3 / 4 of the thickness;

（4）Fillet requirements of custom aluminium die casting design:

On the custom aluminium die casting, the connection between the wall and the wall, no matter the root of right angle, acute angle or obtuse angle, blind hole and groove, shall be designed as the round corner. Fillet connection is not used only when it is expected to be determined as the part of the parting surface, and the rest parts must be fillet generally. The fillet should not be too large or too small, too small customer aluminium die casting is easy to produces cracks. Too large is easy to produce porosity. Generally, the fillet of custom aluminium die casting is 1 / 2 of the wall thickness ≤ R ≤ the wall thickness; the function of the fillet is to help the metal flow, reduce eddy current or turbulence;

（5）Avoid the crack caused by stress concentration due to the presence of fillet on parts;

When the parts are to be electroplated or coated, the fillet can obtain a uniform coating to prevent deposition at sharp corners;

The utility model can prolong the service life of the die-casting mould, and can not cause the angle to collapse or crack due to the existence of the sharp angle of the mould cavity;

（6）Casting slope requirements of custom aluminium die casting design:

The inclination function is to reduce the friction between the casting and the mould cavity, to take out the custom aluminium die casting easily, to ensure that the surface of the custom aluminium die casting is not strained, and to extend the service life of the custom aluminium die casting mould.

1. Overview of Electric Vehicle Market

   New energy vehicles are an important direction for the transformation and upgrading of the global automotive industry. As a centralized carrier for the integration and innovation of emerging technologies and the automotive industry, new energy vehicles have become the focus of industry competition in the world's major automotive countries. At present, major developed countries and regions in the world regard new energy vehicles as an important strategic direction for future development and accelerate their industrial layout. In 2019, the global sales of new energy vehicles was approximately 2.21 million, an increase of nearly 10% year-on-year, of which pure electric vehicles still accounted for the main force, accounting for 74% of the overall sales of new energy vehicles, and plug-in hybrid vehicles accounted for 26%.

   From the perspective of models, the top ten models with the largest sales of new energy vehicles in the world are Tesla Model 3, BAIC EU series, Nissan Leaf, BYD Yuan/S2 EV, SAIC Baojun E series, BMW 530e/Le, Mitsubishi Outlander PHEV, Renault Zoe, Hyundai Kona EV and BMW i3, among which Tesla Model 3 won the top-selling model with a new sales volume of 300,000 units. In December, 53,000 vehicles were delivered in the month, setting a new record for single-month delivery. Obviously, in the next ten years, electric vehicles will become an increasingly important part of our automotive future. And the demand for aluminum die-casting parts will be increased as well, so what does this mean for aluminum die-casting parts?

2.The influence of aluminum die casting parts on electric vehicles

  Aluminum alloy, which has the characteristics of high strength and strong conductivity, can be used for die-casting electric vehicle parts. It can be cast quickly and reliably, for example by a high pressure die casting process. After casting, a suitable alloy must maintain its properties sufficiently to meet the necessary applications. In recent years, the development of aluminum alloy die-casting technology has generally been through continuous optimization and adjustment of the composition of alloy materials, combined with high vacuum die-casting technology and heat treatment process parameter adjustment, to give full play to the process characteristics of alloy materials, with the help of high-pressure injection and low-speed filling continuously improve the comprehensive mechanical properties of die-casting alloy materials.

3.Electric Vehicle battery housing

  The density of aluminum alloy is 2.7g/cm³, and aluminum alloy has obvious advantages in terms of compression or welding. The density of magnesium alloy is 1.8g/cm³ and that of carbon fiber is 1.5g/cm³. These materials are used to produce battery trays, which will greatly improve the lightweight level of new energy vehicles. As known that the battery housing are mainly uses AlSi10MgFe, ENAC43400, A380 materials for aluminum alloy die-casting. The battery housings die cast from these materials have good plasticity and excellent corrosion resistance, especially no stress corrosion cracking tendency, and good welding performance, making these aluminum materials extremely suitable for the application of this project. In order to ensure the product quality of aluminum alloy die castings, it is necessary to adopt advanced welding technologies such as friction stir welding to ensure that the products are integrated.

  Especially built BEVs use "skateboard"-style platforms, such as Rivian and Volkswagen MEB platforms. Usually, the battery housing is located between the axles, and the motor and control system are installed above the axles.

Which shows a typical method that uses a grid-type (or egg-shaped carton) structure to fix and protect the battery module within the frame and the lower cover (providing both protection and chassis integrity).

4.Summary

  Nowadays, the development of electric vehicles is getting better and better, the annual sales are gradually increasing, the popularity of the public is also getting higher and higher, and it brings more and more opportunities to the aluminum alloy die-casting industry.It is believed that the demand for aluminum alloy die castings for electric vehicles will increase in the near future.

   New energy vehicle chassis       

 New energy vehicle battery

We provide experienced engineering, technical management, and quality assurance teams ready to support the most challenging projects. We have assisted clients with precision machined prototypes, die design, extensive product testing, and volume manufacturing.

20 sets aluminum die casting equipments from 160ton to 3000T, 53 sets CNC machines.

CNC deep hole drilling, micro hole edm drilling, custom drilling, etc.

1.Overview of Engine Mounting Bracket

Engine mounting bracket which is divided into two parts is a component of automobile engine. The first one is torsional bracket, the second one is engine mounting rubber whose main function is fix the shock absorption. Torsion bracket is a kind of engine fastener, which always connected to the engine on the front axle of the vehicle body. It is different from the ordinary engine mounting rubber is that the mounting foot is a rubber pier directly installed in the bottom of the engine, and the torsional bracket is similar to the appearance of an iron bar installed in the side of the engine. There is also a torsional bracket rubber on the bracket, which plays the role of damping.

2. Overview of car engine bracket

The car engine bracket is the part that holds the engine in the car. In most cars, the engine and transmission are bolted together and secured together by three or four bases. Part of the car engine bracket is bolted to the body or frame. The other part holds the engine. The engine is a source of vibration because it has many moving and rotating parts. Car engine bracket's job is not only to hold the engine in place, but also to reduce the engine vibration felt in the car. To further suppress vibration, some car engine bracket are filled with liquid and act as shock absorbers. The car engine bracket does not require any maintenance or regular maintenance and needs to be replaced only in the event of failure or wear and tear.

3. How engine bracket works 

The working principle of engine bracket is to fix the engine firmly on the subframe or engine base of the car. It is one of several mounts that hold the engine and transmission together and in place. In this way, the metal surface of the engine does not friction with the metal surface of the body, allowing the shock wave to pass through the car, and rubber is used to fill the engine bracket. Some automakers use vacuum control or electromagnetic mounting to further control vibration absorption. Problems occur when the installation material begins to deteriorate.

4. Application of Engine Mounting Bracket

• Hybrid electric vehicle

5.The Specification of Engine Mounting Bracket

1.Overview of EV Water-Cooling On-board Charger Case

Vehicle charger is an essential core component of new energy vehicles, and its market scale expands with the rapid growth of the new energy vehicle market. Compared with traditional vehicles, new energy vehicles have three core components, namely: battery assembly means battery and battery management system; motor assembly, or starter motor assembly parts, means the motor and the motor controller.

At present, the vehicle charger has the function of high-speed CAN network and BMS communication to judge whether the battery connection status is correct.Getting the battery system parameters, and the real-time data of the whole group and the single battery before charging and during charging.

By high speed CAN communication network and vehicle monitoring system, upload the working status, working parameters and fault warning information of the charger, and accept the control command to start charging or stop charging. For safety protection measures, it has functions such as ac input over-voltage protection, ac input under-voltage warning and ac input over-current protection.

2.Advantage of EV Water-Cooling On-board Charger Case

Aluminum alloy structural parts have good plasticity, aluminum alloy material special physical properties,so in the ductility and plasticity of the product is much better than the steel material.Aluminum alloy structure has advantages of light weight, small volume, low cost, but also has the waterproof, dustproof and anti-corrosion,the characteristics of aluminum alloy on the heat dissipation can be fast cooling, and the structure can make air cooling and water cooling model charger, effective cooling of high power charger, enable the internal automotive electronic components to small power input, the effect of high power output.

3.Application of EV Water-Cooling On-board Charger Case

1. AC Charger housing

2. DC charger housing

4.Parameter of EV Water-Cooling On-board Charger Case

EMP Tech Co.,Ltd(EMP Die Casting), has more than 20 years’ experience of research& development and manufacturing in custom aluminum die casting industry. EMP is certified ISO 9001, IATF 16949, have an experienced technical management and quality assurance team, advanced production equipments, die design and precise machining capability,and are able to provide good-quality products and services to our customers. It is a technical company dedicated to providing customers with product research and development and precision castings.

Our factory inspection room has CMM,Spectrometer,X-Ray,Tensile tester,Cleanliness tester,Roughness tester,Metallographic tester,Corrosive tester,etc.,for example:

Coordinate Measuring Machining,referred to as CMM, it refers to the instrument that can calculate various geometric shapes and sizes according to the point data returned by the probe system in the three-dimensional measurable space.

Spectroscope,it is a scientific instrument that decomposes complex light into spectral lines. It consists of a prism or a diffraction grating. The spectrometer can measure the light reflected from the surface of the object. The seven-color light in the sunlight is the part of the naked eye (visible light), but if the sunlight is decomposed by the spectrometer, the visible light only occupies a small range in the spectrum, and the rest are spectra that cannot be resolved by the naked eye, such as infrared rays and microwaves. , ultraviolet rays, X-rays, etc. The optical information is captured by a spectrometer, developed by photographic film, or computerized to automatically display numerical instrument display and analysis to detect what elements are contained in the article.

Metallographic tester,it is used to identify and analyze the combined structure of various metals and alloy materials. It is widely used in the factory or laboratory for the identification of casting quality; metallographic analysis after raw material inspection or material processing; and surface coating Some surface phenomena are being studied. It is the metallographic analysis of steel, non-ferrous metal materials, castings, coatings, etc. It is an indispensable instrument for the study of the structure of materials in metallurgy and materials science.

Our die casting inspection and quality control protocol are strictly enforced through IATF 16949 certifications. The 3D CMM sensors, scales and calipers are regularly serviced and calibrated to insure our die cast parts are precise and meet required specifications.

It is our philosophy to keep inspectors quality-conscious; the extra time and effort to focus on your project will enhance the completion of the final product.

There are many types of die casting, whose process can be divided into casting, mold, die casting.

What  is die casting? Die casting is a precision casting method that uses a high pressure to force a metal solution into a complex metal mold. Die casting is abbreviated as die casting, which is a casting method in which a molten alloy liquid is poured into a pressure chamber, a cavity of a steel mold is filled at a high speed, and the alloy liquid is solidified under pressure to form a casting.

Casting dimensional accuracy is high, generally equivalent to 6~7, even up to 4;Good surface finish, generally equivalent to 5~8;

High strength and hardness, generally higher than sand casting by 25~30%, but extended the rate is reduced by about 70%;The size is stable and the interchangeability is good;The thin-walled complex casting can be die-cast. For example, the current zinc alloy die castings have a minimum wall thickness of 0.3 mm; custom aluminum alloy die casting up to 0.5 mm; the minimum cast hole diameter is 0.7 mm, and the minimum pitch is 0.75 mm.

Defination of high pressure aluminum casting

High pressure aluminum casting is a process of pressing molten metal into a sealed mold cavity under pressure. It is held in place by a strong compression force until the metal solidifies. After solidification, the mold is released, opened, and the metal is released. After disassembly, the mold cavity is re-sealed for the next cycle. The stage of exerting extremely high pressure on the molten metal true injection plunger is called strengthening.

Systems in high pressure aluminum casting

This process uses two different systems:

Hot chamber system. The injection system of the hot chamber machine is immersed in the molten metal of the blast furnace. When the piston is pumped, it forces the metal along the nozzle into the mold.

Cold room system. Generally speaking, small parts are made in hot chamber systems, while large parts are made in cold chamber systems because the size of hot chamber machines is limited. Compared with the hot chamber system, the pressure of the cold chamber system is higher.

Advantages of high pressure aluminum casting

Higher production speed. 

Significantly reduced processing operations. 

The welding agent has good surface finish. 

Reducing the total weight of the welding agent can reduce the thickness of the plate wall. 

The mold is durable, so the cost is reduced. 

More complex parts can be made, reducing the number of parts required at a time.

Time Parameter of Die Casting

Holding Time

After the molten metal fills the cavity, the casting is completely solidified under pressure. This period of time is called the holding time, and the holding time is related to the wall thickness of the casting and the metal crystallization temperature.

Retention Time

The time from the end of the holding pressure to the ejection of the casting from the mold opening is called the mold retention time. The mold retention time is determined according to the nature of the alloy, the wall thickness of the casting, and the structural characteristics. Generally, the minimum time for the die casting manufacturing process to eject without deformation or cracking is appropriate.

Temperature of Die Casting

Pouring Temperature

The average temperature of the molten metal poured into the injection chamber to the filling cavity, also known as the molten metal temperature, is usually at the lowest possible temperature, generally higher than the die-casting alloy, while ensuring the filling and quality requirements. The liquidus temperature is preferably 10~20 °C.

Die Casting Mold Temperature

The die-casting mold should be preheated before production, and a certain temperature should be maintained during the die-casting process. The die-casting mold is always in a hot state, which provides a basic guarantee for the filling and solidification of the alloy liquid. The zinc alloy is generally 150~200 °C; the preheating of the die casting mold can avoid the rapid cooling of the molten metal and reduce the fatigue stress of the die casting mold.

We primarily serve the automotive, machinery, industrial, telecom, and electronics industries.

A universal testing machine (UTM), also known as a universal tester,  is used to test the tensile strength and compressive strength of materials.

Telecom Cover Parts Overview

Vehicle telecommunication is often developed as part of the Intelligent Transportation System (ITS). Vehicle telecommunication parts are computer network in which vehicles and roadside units are communication nodes that provide information to each other, such as security warnings and traffic information. They can effectively avoid accidents and traffic congestion. Common telecommunication structures are master-slave transfers and bus transfers.The communication cavity is the main component of the communication component.

The Communication Cavity is composed of resonator tuning screw and so on. The cavity filter adopts a microwave filter with a resonant cavity structure, and the cavity can be equivalent to an inductance parallel capacitor, thus forming a resonance level and realizing a microwave filtering function. Compared with other microwave filters, it has a firm structure, stable and reliable performance, small size, moderate Q value, far parasitic high-end passband and good heat dissipation performance, being used for larger power and frequency to filter out strong out-of-band interference signals. In general, it is better than other microwave filters.

During the process of manufacturing telecommunication parts, the main material is aluminum alloy, because it has the advantages of small density, high mechanical strength, good shock absorption performance, excellent casting performance, easy plating and spraying, and good thermal conductivity, corrosion resistance and oxidation resistance.

As mobile telecommunication systems gradually develop toward high frequencies, RF metal components, as an important internal component of RF devices, will develop toward higher integration and precision, smaller volume, and lighter weight.It is mainly used in telecommunication base station.

Importance of Telecommunication Parts

Any organization will have different forms of communication, some face-to-face, others can use technical communication, this is telecommunication, such as e-mail, phone calls, video conferencing, text messages, browsing the web, download and transfer files, these communications use telecommunications systems. Telecommunications system is a collection of nodes and links that realize telecommunications. The nodes in the system are the devices we use to communicate with, such as a telephone or a computer. 

Telecommunication parts is used to produce these devices. High-quality telecommunication parts is an important guarantee for normal communication, which can ensure the smoothness and stability of communication, as well as the security of communication. Therefore, if you want to maintain normal communication, you need to choose a guaranteed telecom parts.

Telecom Cover Parts Quick Details

Quantity: 2 sets

Quantity: 12 sets

Aluminium die casting die is a tool for casting metal parts, a tool that completes the die-casting process on a dedicated die-casting die forging machine. Can be customized by drawings.

1. Overview of Aluminum casting Radiator

The radiator is a general term for a series of devices used to conduct and release heat. It is widely used in power electronics, communications, various power sources, defense, rolling stock, musical instruments, chassis, automobiles, wind power, high-speed rail and many other industries.

2. Advantages of die casting aluminum radiator

1. Thermal conductivity. The aluminum radiator has the advantages of large heat, fast heat dissipation and high efficiency. The unique chimney-like structure of die-cast aluminum can make the room warm and comfortable in 15 minutes. 

2. Production process. The manufacturing process of die-casting aluminum radiator is complex, because it is easy to be extruded and extruded into various shapes, so it has novel and beautiful appearance, strong decoration, round color and high beauty. 

3. Appearance modeling. As the aluminum radiator originated from the European market, coupled with a strong artistic edification, high-end, elegant, beautiful, fashion and other elements into the aluminum radiator gene, in the diversified market, can be favored by more people who pursue quality of life. 

4. Other advantages. The aluminum radiator is lighter and smarter, easy to handle and install, at the same time, the requirement for water quality in the system is almost zero, and there is no need to do full water maintenance.

3. Application of aluminum alloy radiator

• Electronics, machinery industry.

4. The specification of aluminum alloy radiator

Aluminum Die Casting Valve Parts Product Details:

1. Specification: Custom-made

2. Service: OEM/ODM Service

3. Material: Aluminum alloy

4. Application: Automobile,Truck,EV car,machinery

5. Die Casting Machine Type: Cold Chamber Die Casting Machine

6. Quality Control System: IATF16949, ISO9001:2015

7. Apllied Software: PRO/E, Auto CAD, Solid Works,IGS,UG, CAD/CAM/CAE

8. Surface Treatment: Sandblasting, Deburring, Sanding, CNC Machining, Powder Coating

Advantages of Aluminium Alloy Die Casting Products

1. The microstructure of aluminium casting parts is compact and has high strength and hardness.

Because die casting is the filling of molten liquid metal in a very short time, it is cooled rapidly in die casting die and solidified and crystallized under high pressure. Therefore, the microstructure of aluminium casting parts near the surface layer is fine and dense, which makes aluminium casting parts have high strength, hardness, good wear resistance and corrosion resistance.

2. Aluminium casting parts have good surface quality and high precision.

The dimensional accuracy of aluminium casting parts can reach the i13-i level, even ir9 level at the highest level; the surface roughness r-value of aluminium casting parts usually reaches o.8-3.2 μm or even O.4 μm. Aluminium casting parts have good interchangeability and can produce aluminium casting parts with complex shapes, clear outlines and thin walls and deep cavities. The minimum wall thickness of aluminium casting parts is 0.5mm. At the same time, it can cast clear characters and patterns.

3. High production efficiency, can realize mechanized or automatic production, especially suitable for mass production.

According to the size of the die casting machine, the cold chamber dies casting machine can die-cast 3100 times per hour, or even more. The hot chamber dies casting machine can die-cast 40-1000 times per hour.

4. High material utilization

Aluminium casting parts can be directly assembled and used without machining or with a small amount of machining, and the material utilization rate can reach 60% ~ 80%, or even higher, which means good economic benefits. Because of high precision, good surface quality, less machining allowance or assembly without machining, machining equipment and cost are reduced, and good economic benefits can be obtained.

5. It can simplify the manufacturing process.

Other inserts with special properties can be directly embedded in aluminium parts in automobile die casting production. It can not only meet the requirements of service performance, expand the use of products, but also reduce the assembly process and simplify the manufacturing process.

 ▲   Die-casting process is the process of unifying pressure, speed and time by using three major elements: die casting machine, die casting mold and material alloy. For metal hot processing, the existence of pressure is the main feature of die-casting technology that distinguishes other casting methods. Pressure casting is a fast-developing special casting method with less cutting and no cutting in modern metal processing technology. It is a process in which molten metal is filled into a mold under high pressure and high speed, and crystallized and solidified under high pressure to form a casting. High pressure and high speed are the main characteristics of die casting. The commonly used pressure is tens of megapascals, the filling speed (inner gate speed) is about 16-80 m/s, and the time for molten metal to fill the mold cavity is extremely short, about 0.01-0.2 seconds.

 ▲   The following is the die casting process:

  1) Raw material: This is the raw material for the production of aluminum alloy die casting ingots.

  2) Melting: In order to manufacture aluminum alloy die castings, it must be heated to a certain temperature to melt the aluminum ingot. The general choice of aluminum alloy: 610-700 degrees; different pouring temperatures will affect the mechanical properties and quality. The pouring temperature of aluminum castings should be determined according to specific conditions.

  3) Die casting: The molten metal is in a molten state, and the molten metal is filled into the mold under pressure.

  4) Degating: The sprue sleeve is also called the inlet gate, the in-gate handle, etc., which allows molten aluminum to be injected into the mold.

  5) Deburring: Deburring the die-casting parts, rounding the corners, removing rust and descaling.

  6) Trimming: Decorative surface finishing to improve functional edges and surface appearance.

  7) Shot blasting:

      ✧  Able to clean up purposefully, and clean up wherever needed

      ✧  The angle and spray distance of the spray gun can be adjusted to the best position at any time according to the observation of the operator

      ✧  The moving speed of the nozzle of the spray gun relative to the surface of the casting can also be observed by the operator, and the optimal value can be adjusted at any time to minimize the projectile indentation and improve the cleaning effect.

  8） CNC Machining: CNC Machining ,it is set up and adjust on the CNC machine tool, and then the die casting is processed and manufactured.

  9） Leak test: For products with air tightness requirements, the leak test can quickly identify whether the parts have poor leakage.

 10）Cleaning: Cleaning the product directly or indirectly affects the liquid and dirt, disperses, emulsifiers, and peels the dirt layer to achieve the purpose of cleaning. Even without damage to the surface of the product, the deep holes, crevices, and hidden areas of the parts can also be cleaned to make the product shinier.

 11）Packaging: After the finished product comes out, it will be fully packaged to prevent damage to the finished product.

  ▲   Summary: The casting process of aluminum alloy die castings is to fill the mold cavity with molten metal first at low or high speed. The mold has a movable cavity surface, which is pressurized forged with the cooling process of the molten metal. Eliminate the shrinkage cavity and porosity defects of the blank, and also make the internal structure of the blank reach the forged broken grains. The comprehensive mechanical properties of the blank have been significantly improved. In addition, the rough produced by this process has an outer surface finish of 7 (Ra1.6), which has a metallic luster like the surface produced by the cold extrusion process or machining.

Our team at EMP is committed to providing you the best result for your custom projects, utilizing the most advanced equipment and techniques available today.

We are certified ISO 9001, IATF 16949, and deliver an output of 5,000 tons of precision aluminum alloy products each year.

With great commination skills and experience, we are willing to work through problems, and proactive in offering advices.

Pump parts

A pump is a machine for conveying or pressurizing a fluid. It transfers the mechanical energy or other external energy of the prime mover to the liquid, so that the liquid energy increases. Pump parts china are mainly used to transport water, oil, acid and alkali liquid, emulsion, suspended emulsion and liquid metal and other liquids, also can transport liquid, gas mixture and liquid containing suspended solids.

From the performance range of the pump, the flow of the giant pump per hour can reach hundreds of thousands of cubic meters above, and the flow of the micro pump per hour is in the tens of milliliters below; The pressure of the pump can be up to 19.61Mpa(200kgf/cm2) from normal pressure. The temperature of the liquid to be transported can be as low as -200 ℃ or as high as 800 ℃. Pumps transport a wide range of liquid, such as water (clean water, sewage, etc.), oil, acid and alkali, suspension, and liquid metal.

Types of Valve Parts China 

For liquids, environment types and operating systems are different, so there are a variety of valve types in China, each type can meet specific needs for different occasions. Some valves can be throttled, some valves are corrosion resistant and are specially designed for specific liquids, some valves are suitable for high pressure environments, and some can stop the flow of liquids. Buyers need to choose specific valves according to different needs and commercial uses, and each product has its own advantages and disadvantages. 

It is important to understand these differences and how they affect the application or operation of the valve. The methods of controlling flow can be very different. Generally speaking, there are four: Move or rotate a disc, and slide a flat, cylindrical, or spherical surface, also can control the flow according moving a flexible material into the flow passage.controlling flow has a characteristic that makes it the best choice for a given application of function. ways to control flow through the valve.

Industries of Pump Parts

In agricultural production, pump is the main drainage and irrigation machinery. Pump parts in china are in great demand. Our country rural area original broad, every year rural area needs a large number of pumps, generally speaking, agricultural pumps accounted for more than half of the total output of the pump. 

In the shipbuilding industry, there are generally more than 100 pumps used on each ocean liner, and the types are various. 

Others such as urban water supply and drainage, steam locomotive water, lubrication and cooling machine tools, the textile industry in the transfer of bleaching and dye, pulp in the paper industry, as well as the food industry in the transfer of milk and sugar food, all need a large number of pumps. 

Valve Parts

The device that controls the flow of water in the pipeline by changing the cross section of the pipeline is called valve. Valve parts in china has many kinds, such as bottom valve, gate valve, reverse valve and flap valve.

Valve Parts details

1）The bottom valve

Also calls as one-way valve, artificial water filling to prevent leakage and use, used to prevent leakage when filling water manually.

2）Gate valves

Installed on the outlet pipe, for closing valve (low pump) start, close valve stop, adjust the flow of accessories. Single valve should be selected according to the diameter of the water pipe, valve type, performance, specifications, working pressure and other correct choice.

3）Reverse valve

Installed on the water pipe, so as to prevent accidents when stop out of the water in the pool and outlet pipe back a one-way valve.

4) Flap valve

Installed in the outlet pipe outlet, in order to prevent the water in the pool to the outlet pipe backflow of a one-way valve, generally a complete set of water pump plant supply.

Motor is a kind of electromagnetic device which realizes the conversion and transmission of electric energy according to the law of electromagnetic induction. Its main function is to produce a driving torque as electrical appliances and a variety of mechanical power source.

Electric Vehicle Motor Parts Function

A motor is composed of motor stator, motor rotor, housing, cover, bearing, motor blades and so on. All of them play an essential role in different position. 

• Motor stator whose function is generating a rotating magnetic field consists of stator core, stator winding and frame. 

• Motor rotor is a rotating parts of the motor, which is used to realize electrical and mechanical energy conversion. 

• Motor housing cover whose main characteristics are water proofing, dust proofing and corrosion preventing is the motor protection device, through aluminum die casting, surface rust prevention and plastic spraying can well protect the internal equipment of the motor. 

• Electric motor housing is a back cover installed at the back of the motor housing, which is composed of cover body, bearing and brush plate. The quality of the electric motor housing directly affects the motor. 

• Motor bearing is an important parts of modern mechanical equipment, its main function is to support the mechanical rotating body, reducing the friction coefficient in the process of motion and ensuring the accuracy of rotation. 

• Motor blade is also located at the tail of the motor and used for ventilation and cooling of the motor.

Each of them has their own tasks, a motor can’t run independently without each of parts. Without the motor, the vehicle can’t run. All of the motor parts are promoting, coordinating and connecting with each other to make the motor run smoothly.

Electric Motor Drive End Bracket Product Details:

1.Specification: Custom-made

2.Service: OEM/ODM Service

3.Material: Aluminum alloy

4.Application: Automobile,Truck,etc. /Electric Vehicle Battery Housing

5.Die Casting Machine Type: Cold Chamber Die Casting Machine

6.Quality Control System: IATF16949, ISO9001:2015

7.Apllied Software: PRO/E, Auto CAD, Solid Works,IGS,UG, CAD/CAM/CAE

8. Surface Treatment: Sandblasting, Deburring, Sanding, CNC Machining, Powder Coating

Post-processing mainly deals with the surface of the workpiece to achieve a certain degree of smoothness and brightness, eliminates surface stress and internal stress, so that the subsequent processes can be carried out smoothly.

Our commitment to continuous research and development in the aluminum die casting field has awarded us with more than 17 patents, and a growing customer base spread over 25 countries worldwide.

A roughness tester is used to quickly and accurately determine the surface texture or surface roughness of a material. A roughness tester shows the measured roughness depth (Rz) as well as the mean roughness value (Ra) in micrometers or microns (µm).

Quantity: 1 set

Quantity: 12 sets

The Engine Cylinder Lower Block is located between the engine cylinder and the oil pan.

The heat sink enclosure uses aluminum with a high thermal conductivity as the main body of the heat sink, which has the advantages of light weight, corrosion resistance, strong thermal conductivity, non-magnetic and strong plasticity. Heat sink enclosure can be customized according to customer drawings.

Overview of aluminum heat sink enclosure

Aluminum is light in weight and easy to manufacture. Aluminum alloy is the most common radiator material. The cost of aluminum is lower than that of copper and has high performance-to-price ratio, so it is an ideal choice for most radiators. Its heat transfer capacity, or thermal conductivity, is about half that of copper. This limits the distance at which heat moves and conducts from the heat source in the radiator base. The radiator is designed to maximize the surface area in contact with the coolant.

The aluminum mounting brackets are made of aluminum alloy, which can not only be integrated, but also stable and safe.

To meet the technical requirements for manufacturing aluminum die casting parts used in new energy vehicle and 5G industry, our factory has equipped itself with a new machine in 2020 ---the large-scale friction welding equipment .

This equipment can help with manufacturing various products like electric vehicle products, battery housing, motor housing and controller housing , telecommunication filter and heat sink parts.

If any of your project involves above parts, EMP team is happy to help.

With the development of science and technology, people's requirements for the safety and beautiful appearance of die casting products are constantly improving. The evaluation of the quality of the parts is different with different uses. This paper analyzes how the die design affects the quality of aluminium dies casting. How produce high-quality parts is of great significance to save materials, energy, shorten manufacturing hours and improve economic benefits.

Factors affecting the quality of die casting

Many factors affect the quality of die casting part, such as the type and quality of the die-casting machine, the geometric structure of die-casting parts, the rationality of technical requirements, the structure of die, the technical level of operators, etc.

1. Design of die casting

The designer should first fully understand the user's requirements and working conditions, as well as the stress of the die casting. Then the designer chooses the appropriate material according to the use requirements and working environment and understands the die casting performance of the material. In the design, special attention should be paid to making the die casting structure as simple as possible on the premise of meeting the use requirements. The wall thickness shall be proper and uniform, and the necessary die inclination shall be reserved, otherwise, the defects such as pit, air hole, shrinkage porosity, under casting, pull mark, crack, deformation and so on will appear on the die casting. The requirements for dimensional accuracy of die-casting parts should be reasonable, otherwise, it will cause unnecessary troubles to die design, die processing, formulation and management of process conditions, and also cause a large number of unqualified products.

2. Die structure, machining accuracy and die material selection

Die casting is made by die casting. There is no doubt that the design, processing and selection of die materials are closely related to product quality. If the die structure is unreasonable, no matter what measures are taken from the process, it is difficult to make the product qualified. Also, the quality of the product and the shelf life of the die will be affected by the die material, the processing accuracy, the surface roughness, the processing trace, the micro-crack of the heat treatment, the thickness of the nitriding layer and the improper assembly of the die.

3. Shrinkage of casting materials

The average shrinkage of casting material is usually selected when it is given in the form of an average percentage or percentage with a certain range of change. For high-precision die-casting parts, we should pay special attention to the material shrinkage when we design the mould. If necessary, we can make a test mould first, and then design and manufacture the mould for mass production after obtaining the required data on the test mould.

4. Formulation and implementation of the die casting process

The formulation and implementation of the die casting process are related to the quality of die-casting equipment and the technical level of operators. Under the condition of the existing die-casting equipment in China, it is difficult to achieve stable, reliable and accurate control of the die-casting process parameters. The realization of basic control of the die casting process is the process of combining and using die casting equipment, die casting materials and dies. If the process and main parameters are not strictly carried out, the die casting will have shrinkage, deformation, under casting and unqualified dimensions.

Relationship between die casting quality and mould

Die is the main tool for die casting. Therefore, when designing the die, we should try our best to make the overall structure of the die and the structure of die parts reasonable, easy to manufacture, easy to use, safe and reliable. To keep the die from deforming in the die casting, the molten metal can flow stably in the die, the casting can be cooled evenly, and the die casting can be fully automatic without failure. Besides, according to the production batch, material conditions and other reasonable selection of suitable mould materials.

      1. The structure of the mould and its parts should be reasonable

From the point of view of strength, it is better to design the die parts as a whole. This kind of mould can be firm and durable, not easy to be damaged and deformed in use. However, if the shape of the die-casting is complex and the parts of the die-casting are complex, it will be difficult to process the die-casting and the accuracy of the processing is not high. If the mould parts are made into a combined type, the processing is greatly simplified, and it is easy to obtain high processing accuracy, and then high-quality die-casting parts can be obtained.

2. Influence of cavity number

To determine the number of cavities, we should consider the equipment capacity, the difficulty of mould processing, the production batch size, the precision requirements of castings, etc. Especially the multi-cavity mould. Because of the difficulty of die machining, the large error of dimension accuracy, and the difficulty of balancing the runner configuration, the performance of each cavity casting may be inconsistent. The first mock exam is required for high precision, so when the geometry is complex, it is best to use one cavity for one mould. Small castings depend on the situation.

3. Design of pouring system

The gating system is not only the channel for liquid metal to fill the die casting mould but also plays an important role in regulating the flow velocity and pressure transfer of the melt as well as the exhaust conditions and the thermal stability of the die design for die casting. Therefore, it is necessary to analyze the structural characteristics, technical requirements, alloy types and characteristics of the casting to design the gating system. It is necessary to consider the type and characteristics of the die casting machine to design a reasonable gating system.

4. Design of exhaust system

The mould shall be equipped with an overflow groove and exhaust channel with sufficient overflow range, which is very important to ensure product quality. People often ignore the phenomenon that the overflow channel is blocked up prematurely by the incoming liquid metal. A reasonable structure shall be adopted to make the liquid metal flow into the deeper part of the overflow tank first, to ensure that the vent hole is always open for the longest time. Besides, the overflow tank shall be equipped with an ejector rod to remove the metal in the overflow tank.

5. Mould temperature

The temperature of the die casting die is an important factor that affects the quality of the casting. Improper mould temperature not only affects the internal and external quality of the die casting (such as porosity, shrinkage cavity, porosity, mucous membrane, coarse grain and other defects), but also affects the dimensional accuracy of the casting, even the deformation of the casting, causes the crack of the die casting, forms the net burrs on the surface of the casting that are difficult to remove, and affects the appearance quality of the die casting. Take the aluminium alloy as an example, the alloy temperature is 670-710 ° C cast into the mould. In the long-term production practice, it is concluded that the best temperature of the mould should be controlled at 40% of the casting temperature. The temperature of aluminium alloy die casting die is 230-280 ° C, which is favourable for obtaining high quality and high yield castings. Generally, the mould does not need gas or electric heating but uses preheating and cooling devices. These devices use oil as the medium according to the requirements to preheat and cool the mould.

6. Dimensions of formed parts

When calculating the size of the die casting part, the shrinkage of die-casting materials should be in line with the actual situation, otherwise, die casting components produced will be unqualified. If necessary, the size of the die casting shall be calculated after the actual measurement of the test die. For high-precision products, we even need to take into account the thermal expansion of die-casting parts and the influence of preservation and use environment on the dimensional accuracy of products after die-casting.

7. Influence of dying joint position

The position of the parting surface will affect the mould processing, exhaust, product demoulding, etc.

Generally, the parting surface will leave a trace line on the product, which will affect the surface quality and dimensional accuracy of the product.

Therefore, in the design of the parting surface position, in addition to considering product demoulding, mould processing, exhaust and other issues, we can place the parting surface position where the product surface quality requirements are not high or the dimensional accuracy is not high.

8. Mould deformation effect

We have dedicated over 15% of our staff to our quality control efforts and implement quality control in all phases of production.

We are located in a region known for its world-class technical development and manufacturing capabilities, industrial facilities, and extensive logistics and transportation network. We're here to turn your ideas into reality quickly, accurately and at a competitive price.

We've been serving the top brands like Mercedes Benz, Continental, Huawei from the begining of our foundation.

1.Overview of Engine Oil Pan

Oil pan is an important part of automobile engine and an indispensable part of engine lubrication system.By sealing the lower crankcase, the oil on the moving surface of the engine is collected and stored, oil to prevent aging, part of heat loss,at the same time through the oil pump bracket, tubing, splash board functions focus on parts, effectively improve the engine performance, reduce manufacturing cost.

2.Application of oil pan

Hybrid electric vehicle

3.The Specification of Oil Pan

The contour tester is an instrument for testing and inspecting the contour of an object. As a precision measuring instrument, it is widely used in automobile manufacturing.

Quantity: 12 sets

Common aluminum die-cast car seat spare parts include seat windshields, automotive seat parts and seat stops.

CNC Machine

Quantity: 1 Set

Friction welding overview

Friction welding is a pressure welding method that uses the heat generated by the relative frictional movement of the weldment to achieve reliable connection of materials. 

The welding process is under the effect of pressure, the friction between the materials to be welded increases the temperature of the interface and its vicinity and reaches in the thermoplastic state, with the action of upsetting force, the interface oxide film is broken, the material undergoes plastic deformation and flow, and the joint is formed by the interface element diffusion and recrystallization metallurgical reaction.

EMP Tech Co., Ltd, offering professional friction welding services, can finish many kinds of friction welding, including the continuous drive friction welding, rotational friction welding and orbital friction welding, etc..

Friction welding aluminum

The surface temperature of friction welding is the temperature of the heat source of friction welding, which will directly affect the heating temperature and temperature distribution of the joint and the deformation and diffusion of the joint metal. In the process of friction heating, the friction surface can also adjust the friction heating power through the influence of the friction coefficient, so that the heating power and the temperature of the heat source are in balance. Welding test and production practice show that when the diameter of the workpiece increases, the rotation number increases and the friction pressure increases, the temperature of the friction welding surface increases. Otherwise, the surface temperature of friction welding will be reduced.

Friction welding services overview

Heating deforms the material, and the rotating tool stirs the material at the weld. In this way, friction welding technology creates a uniform structure with excellent performance. The whole process is emission-free. When welding must be very tight, friction welding is the preferred method. It can connect the workpiece with repeatable pressure and medium seal. Friction welding can be optimized and integrated into industrial batch production. The result is top quality that is easy to copy.

As a machinery parts manufacturer, we provide various products and services in this area, and actually friction welding services and production, continuous drive friction welding, phase-controlled friction welding, inertial friction welding and friction stir welding are more common used.

Advantages of friction welding services

Durable, medium-sealed and pressure-sealed welds.

Height, repeatable seam quality.

Low warping joint.

No pores or hot cracks.

No exhaust emissions, no shielding gas, powder, welding wire and other auxiliary materials.

In actual friction welding services and production, continuous drive friction welding, phase-controlled friction welding, inertial friction welding and friction stir welding are more common.

Friction welding machine is mainly used for welding of medium-sized shaft parts. It can weld a wide range of metals, and has the characteristics of stable performance, high production efficiency and low energy consumption, which is important for friction welding companies.

Orbital friction welding

Rail friction welding is similar to rotary friction welding, but the two welding parts of rail friction welding rotate in the same direction and at the same speed,with axes offset up to 3 mm. At the end of the welding, the two parts return to the common shaft, the relative motion ends, and the welding relay remains intact or increases. Rail friction welding has the advantage of uniform surface velocity in the whole contact zone. You can connect non-circular components and multiple individual parts in a friction welding sequence. Although rail friction welding has been demonstrated in many materials and joint configurations, it is rarely used in industry.

The quality of aluminum die castings has a great impact on the performance of automotive and mechanical parts. For example, the sizes of the impellers, casings and inner parts of various types of pumps, the accuracy of the profile and surface roughness directly affect the working efficiency of pumps and hydraulic systems, energy consumption and the development of cavitation. The strength and resistance to coldness and heat of cast aluminum parts such as cylinder blocks, cylinder heads, cylinder liners, piston rings, and exhaust pipes will directly affect the engine's working life.

So how do we check the quality of aluminum die castings?

You may follow the below procedures to check the quality of aluminum die castings:

1. Aluminum alloy composition analysis with spectrometer ;

2. Analyze the crystallization of castings with metallographic analyzer;

3. Detect the internal quality of the casting with X-ray flaw detector

4. Check whether there are cracks on the casting surface with Fluorescence analysis;

5. Detect the mechanical properties of castings with universal testing machine

6, Check the size of the measurement with calipers, height rulers, three-coordinates for dimensional detection of castings, and so on.

1. Visual inspection method of aluminum alloy die casting

We usually use visual inspection. Visual inspection conditions: under the approximate natural light of 300-600lx natural light (such as the distance between 40W fluorescent lamp and 500mm). The distance between the examiner and the target is 600-650mm, and the viewing angle is 45-90 °. The visual acuity level of the examinee should be above 1.0 (including after correction).

2. Common appearance quality problems of aluminum alloy die casting

(1) Die sticking

Along the direction of demoulding, due to the adhesion of metal, the manufacturing slope of the mold is too small, resulting in the scratch marks on the surface of the casting, which is called the scratch surface when it is serious

(2) Layering

There are obvious metal layers on the casting

(3) crack

There are straight or wavy lines on the surface of the casting, which are narrow and long, and tend to develop under the action of external force

(4) deformation

The geometry of the casting does not conform to the drawing due to uneven shrinkage or external forces

(5) flow mark

There is no development trend for the striation on the surface of die casting with the same flow direction of liquid metal

(6) watermark

The smooth lines on the surface of the casting are visible to the naked eye, but cannot be felt by hand. The colour is different from that of the substrate technology. It can be removed by a few strokes with 240 #sandpaper

(7) cold separation

On the surface of die casting, there are obvious, irregular and sagging linear lines (there are two kinds of penetration and no penetration). shape

It is small and narrow, and sometimes the joint edge is smooth. Possibility of disconnection

(8) turtle crack

Because of the thermal fatigue on the surface of the mold cavity, the castings, the net convex traces and metal thorns on the surface are formed

(9) depression

Most of the surface of casting has a smooth concave phenomenon

(10) compression injury

Marks left by extrusion during stamping or machining of trimming die

(11) bruise

Deformation trace of the product surface and corner caused by collision

(12) undercast

There are insufficient parts on the casting surface, resulting in unclear contour

(13) Flash, burr

Sheet metal or rough, sharp edges and corners appear on the edge of the parting surface

(14) dislocation

One part of the casting is staggered with the other part on the parting surface, resulting in relative displacement

(15) peeling

The phenomenon of peeling off of casting surface and matrix

(16) stain

A spot on the surface of a casting that is different from the base metal, is usually formed by coating carbides

(17) Material shortage and collapse

Defects caused by external force striking the nozzle or trimming die

(18) Thimble print

A mark on the surface of a casting that protrudes or recesses as a result of a die thimble

(19) sand hole

In die casting, because of the particularity of die casting, aluminium parts are formed under the condition of high temperature, high speed, and high pressure. So there are inevitable holes in the die casting. We call these holes sand holes.

(20) shrinkage cavity

In the process of casting solidification, the hole with dark colour and irregular shape formed by insufficient metal compensation is called shrinkage cavity

(21) stomata

A hole like a defect in a die casting caused by entrapment of gas. Visual inspection or flaw detection after dissection. The pores have a smooth surface and round shape.

EMP is a global, full-service manufacturer of precision aluminum die casting products. With more than 20 years' experience in research & development, manufacturing, and precision machining for the aluminum die casting industry, we are proud to work with some of the world's top automotive, engineering, electronics, and telecommunications companies.

We manufacture a diverse range of products in the automotive, electronics, telecommunications, and electric motor markets.

We help to solve your problems, from design to reality.

Cutting aluminum tubing, cutting aluminum plate, cutting aluminum angle, cutting thin aluminum sheet, cutting aluminum bar, cutting aluminum trim, cutting rectangular holes in aluminum, cutting aluminum flat bar, etc.

Our factory inspection room has CMM, Spectrometer, X-Ray, Tensile tester, Cleanliness tester, Roughness tester, Metallographic tester, Corrosive tester, etc. Our die casting inspection and quality control protocol are strictly enforced through IATF 16949 certifications. The 3D CMM sensors, scales, and calipers are regularly serviced and calibrated to insure our die-cast parts are precise and meet the required specifications.

It is our philosophy to keep inspectors quality-conscious; the extra time and effort to focus on your project will enhance the completion of the final product.

According to the ISO/IATF16949 system requirements, the company builds a quality management system and conducts continuous improvement during operation to provide customers with quality products and services. We are eagerly looking forward to cooperating with you to create a bright future together.

CNC Machining is directly changing the size, shape, mutual position, surface roughness or properties of raw materials or semi-finished products to make them into finished products. 

Including: casting, welding, electroplating, heat treatment, machining and assembly processes.

The process of removing the surface material of the part by metal cutting, the process of obtaining the finished product is called a machining process.

Leak testing is used to determine whether products pass a specified leak limit. Leaks occur when a gas or liquid flows from a higher pressure side to a lower pressure side of a part and are caused by holes, cracks, weak seals or permeable areas in a product.

Quantity: 12 sets

CNC EDM Equipment

Quantity: 2 Sets

Recently, The corona virus is spreading wildly in America and Europe, we pray everyone is safe, better take precautions like wearing masks wherever you go and disinfecting your hands when you go back home.

However, with the spread of the global epidemic situation, epidemic prevention materials such as masks have been sold out everywhere, and many countries with severe epidemics are in shortage of epidemic prevention materials and people are in panic buying them.

To fight against the Covid-19 epidemic, many of our clients in Germany, Italy, UK and US asked us to purchase medical face masks for them, and we've managed to find one manufacturer who produces well qualified KN95 medical mask as the situation in China is under control well.

Therefore, we can take care of export of a large number of KN95 mask. KN95 mask is the same as the international N95 standard, with 95% filtration. We can get the KN95 face masks delivered to your doorstep, and we've purchased and shipped out 100,000+pcs to several of our customers last week.

If you might require these as well, just let us know, we are happy to help. 

Product details：

The global die casting manufacturing centre is transferred to the mainland of China. China's precision dies casting enterprises are mainly distributed in Guangdong, Jiangsu, Zhejiang, and other places. Most of the large-scale and specialized enterprises are concentrated in the Pearl River Delta and the Yangtze River Delta. Due to the dominant position of Asia, especially China, in market demand, raw material supply, labour resources, industrial chain supporting, policy support, and the rapid development of China's automobile industry, since the 21st century, the global die casting production has shown a trend of transfer to Asia, especially to the mainland of China, which is still continuing. The expansion of market scale and the entry of international excellent enterprises have promoted the technical level and management level of domestic die casting manufacturers, and further promoted the development of the industry. China has formed the Yangtze River Delta, Pearl River Delta, northeast three provinces, southwest region and other pressure casting industrial clusters, of which the Yangtze River Delta and the Pearl River Delta are the most prominent. The two regions have an active economy, developed supporting industries and obvious regional advantages.

Advantages of Aluminium Parts in Automobile

Under the premise of ensuring vehicle strength and safety performance, vehicle lightweight can improve vehicle power, reduce fuel consumption and exhaust pollution by reducing vehicle quality. Reducing the mass of different parts such as body, interior, and exterior decoration, power system and so on will help to reduce the energy consumption in the process of driving. Aluminium parts in automobile is light, recyclable and easy to form, so it is widely used in automobile body and parts. In theory, automotive aluminum parts can reduce the weight of steel cars by as much as30% - 40%, of which aluminium engine can reduce 30%, the aluminum radiator is 20% - 40% lighter than copper, the all-aluminium body is 40% lighter than steel, and aluminum hub of the automobile can reduce 30%. Therefore, aluminum alloy material is an ideal material for automobile lighting.

Reducing the vehicle weight can reduce the engine load, improve the driving performance of the vehicle, effectively reduce the braking distance, make the steering and bending process more flexible so that the vehicle is more stable, and the aluminum alloy structure can absorb and disperse more energy when impacted, so it is more comfortable and safe. As a result, in the next decade, the aluminum penetration rate of all major parts of the car will be significantly increased, and the penetration rate of the aluminum engine hood is expected to increase from48% in 2015 will increase to 85% in 2025, and the penetration rate of aluminum doors will increase from 6% in 2015 to 46% in 2025. Specifically reflected in the average aluminum consumption per vehicle in North America in 1975, the average aluminum consumption per vehicle in North America was 38kg, which increased to 180kg in 2015. In 40 years, the aluminum consumption per vehicle in North America continued to increase, with a compound growth rate of 4%. It is estimated that China will achieve 190 kg/vehicle aluminum consumption in 2020, which is in line with North America, with a corresponding market space of about 152 billion yuan.

The concentration of the die-casting industry in China is relatively low. There are about there are more than 12000 enterprises, of which more than 70% are die-casting enterprises. The enterprises are mainly distributed in Guangdong, Jiangsu, Chongqing, and other places. Most of the large-scale and specialized enterprises are concentrated in the Pearl River Delta and the Yangtze River Delta, and the proportion of large-scale die-casting enterprises is only about 10%. There are two main types of domestic enterprises with a large production scale of automobile die-casting, one is the supporting enterprise in automobile field, which is subordinate to the group company of downstream industry; the other is the independent automobile precision die casting production enterprise, which is specialized in the production of automotive casting components, and has established a relatively stable long-term cooperation relationship with downstream customers.

We are here whenever you need, any of your inquires or questions will be handled within 12 hours.

EDM micro drilling, wire EDM aluminum, etc.

Our factory inspection room has CMM, Spectrometer, X-Ray, Tensile tester, Cleanliness tester, Roughness tester, Metallographic tester, Corrosive tester, etc. 

Our die casting inspection and quality control protocol are strictly enforced through IATF 16949 certifications. The 3D CMM sensors, scales, and calipers are regularly serviced and calibrated to insure our die-cast parts are precise and meet the required specifications.

It is our philosophy to keep inspectors quality-conscious; the extra time and effort to focus on your project will enhance the completion of the final product.

According to the ISO/IATF16949 system requirements, the company builds a quality management system and conducts continuous improvement during operation to provide customers with quality products and services. We are eagerly looking forward to cooperating with you to create a bright future together.

Surface treatment overview

Surface treatment is a process for artificially forming a surface layer on the surface of a base material that is different from the mechanical, physical, and chemical properties of the base body. The purpose of surface treatment（E-coating/KTL） and finishes is to meet the requirements of product's corrosion resistance, wear resistance, decoration and other special functions.

KTL surface treatment

KTL provides products with long-term anticorrosion, high resistance to mechanical damage, salt water resistance and chemical resistance. 

During the KTL process, the product is completely immersed in a liquid-colored KTL bucket, soaked through an anode and placed on both sides and bottom of the KTL, and charged with a positive electrode. 

In this process, the immersed product is connected to the negative electrode and acts as the cathode. 

KTL is used as the final coating or primer under the paint and is suitable for all products and their initial sandblasting, providing the highest quality surface treatment.

Aluminum die castings can be used in wiper systems, engine systems, filter systems, air conditioning systems, precision compressor parts, shock absorption systems, braking systems, ABS systems, rearview mirror systems, power steering control systems, motors for fuel vehicles End caps, pump housing, and more.

Quantity: 12 sets

Universal Rocker Milling Equipment

Quantity: 3 Sets

Ultrasonic cleaning is the use of ultrasonic cavitation, acceleration and direct flow in liquid to directly and indirectly affect the liquid and dirt, so that the dirt layer is dispersed, emulsified and peeled to achieve the purpose of cleaning. It take the advantages of good cleaning, High cleanliness, fast cleaning speed, improve efficiency, no damage to the surface of the parts, deep holes, fine seams and hidden area of the parts can also be cleaned and so on.

Preheating requirements of cast aluminum mold casting in process

Die casting aluminum parts  It is necessary to preheat the casting aluminum die before die casting. The unheated die will make the aluminum liquid cool too fast and reduce the fluidity, making the casting easy to have problems such as cold separation, incomplete moulding, inclusion, porosity, etc. At the same time, the mold is strongly impacted and the stress is doubled, which makes it easy to be destroyed. Therefore, preheating can improve the surface quality of castings and prolong the service life of dies.

Generally, the preheating temperature is controlled at150 ℃ ~ 300 ℃, and it can be used after holding for about 0.5h.

Do not use molten metal(aluminum water) directly to preheat the mold, because if the cold mold directly contacts the hot liquid metal, it is bound to be impacted by heat, resulting in thermal erosion, accelerating the surface cracking and peeling of the mold caused by thermal fatigue.

Cooling requirements of cast aluminum moldcasting in process

In the continuous die casting production, the temperature of the aluminum mold often increases. The high temperature not only causes the liquid metal to bulge but also causes the slow cooling of the casting, resulting in the coarse grain and the decline of the quality of the high pressure die casting aluminum. Therefore, when the mold temperature is too high, cooling measures should be taken.

(1) Water cooling: a cooling water channel is arranged on the aluminum alloy die-casting die to make the circulating water flow into the forming insert or core and bring the heat out of the die. The cooling efficiency of water-cooling is high, which can effectively reduce the temperature of the cavity surface, but increase the complexity of die-casting mold structure, mainly used for mold with large heat dissipation. In order to prevent condensation on the surface of the cavity, the temperature of the cooling water should be higher than the room temperature.

(2) Air cooling: for the parts that are difficult to be cooled by water in the die casting mold, air cooling can be adopted, and blower or compressed air can be adopted for air cooling. Air cooling can not only cool the aluminum alloy die-casting mold, but also blow the coating evenly, disperse the volatile gas of the coating, and reduce the porosity of the casting. The cooling temperature of air cooling is much lower than that of water cooling.

(3) Heat pipe cooling: mainly used for small parts that are difficult to be directly cooled by cooling water. In the small parts to be cooled, the heat pipe is used to export the special heat, and then the cooling water is used to cool the heat pipe.

Storage management after using

After the use of the aluminum mould, the mold cavity shall be cleaned in time to effectively remove the residual aluminum. After the cooling, the rust prevention treatment shall be carried out, and the mold shall be put in storage and placed horizontally for centralized management for reuse. The service life of aluminum mold can be effectively extended by grasping the relevant links of die cast tooling, manufacturing, use and maintenance management.

Cast aluminum is a process in which molten aluminum is poured into a mold and cooled to form aluminum parts in the desired shape. Castings obtained by casting aluminum are called aluminum castings.

During the casting process, aluminum castings are prone to defects such as internal looseness, shrinkage, and porosity. these castings with defects are after machined, the surface dense layer components are removed, but the internal tissue defects are exposed.

Defective appearance:

Casting crack: It is a crack formed at a higher temperature. It is easy to appear when the volumetric shrinkage of the casting is large and the thermal expansion coefficient is large.

Heat treatment cracks: Due to overheating or overheating caused by heat treatment, often showing trans-crystalline cracks.

The causes of cracks and suggestion:

1. The structural design of the casting is unreasonable, with sharp corners, and the thickness of the wall changes too much. If cracks occur in this case, the structural design of the casting should be improved to avoid sharp corners, and strive to strengthen wall thickness and smooth transition.

2. Cracks can also occur in sand molds (cores) with poor yielding properties. Measures should be taken to increase the concession of the sand mold (core).

3. Partial overheating of the mold will cause cracks, and it should be ensured that all parts of the casting are solidified simultaneously or sequentially, and the design of the pouring system is improved.

4. If the pouring temperature is too high, cracks will also occur, and the pouring temperature should be appropriately reduced.

5. When the casting is taken out from the casting mold too early and the casting will be deformed, the thermal correction method should be used. The cooling time of the mold should be controlled.

6. The heat treatment is overheated, and the cracks are generated after the cooling rate is excessively exciting. The thermal correction method is used when the casting is deformed. Correctly control the heat treatment temperature and reduce the quenching cooling rate.

EMP Tech Co., Ltd.(EMP Die Casting)

Address: NO.38 Duanzhou 3rd Road, Zhaoqing(526060), Guangdong, China

Email: [email protected]

Tel: +86-0758-2203787

Mobile: +86-136-9425-7500

Whatsapp: +86-137-1008-7276

Skype: [email protected]

Recently, EMP Die Casting Co., Ltd has become a rising star in China’s die casting industry. Thanks to all the staff’s efforts, we have made great strides in our casting business, reached 37 million USD revenue in 2019. 

To make more progress, EMP casting company is investing in more automatic equipment to improve its production mode to a new innovation-oriented process mode, which made us more competitive in the automotive market and help our customers cut down their sourcing cost. 

All members of EMP believe their great efforts will take EMP to the next level in the near future.

EMP is a leading manufacturer of precision aluminum die casting parts worldwide. With more than 20 years' experience, we are proud to work with some of the world's top automotive, engineering, electronics, and telecommunications companies.

Turnkey service offered for all aspects of aluminum die casting from tooling design and testing, to high-pressure aluminum die casting, CNC machining, post-processing and surface finishing.

We have passed IATF 16949 and we've been serving the top brands like Daimler, Continental, Ford, Misutba, etc.

Our team at EMP is committed to providing you the best result for your custom projects, utilizing the most advanced equipment and techniques available today. We are committed to becoming the most reliable and innovative supplier in Die Casting industry and, as our LOGO implies, EMP will be your stranger-supplier-supporter-partner-friend.

Hardness is a characteristic of a material, not a fundamental physical property. It is defined as the resistance to indentation, and it is determined by measuring the permanent depth of the indentation.More simply put, when using a fixed force (load)* and a given indenter, the smaller the indentation, the harder the material. Indentation hardness value is obtained by measuring the depth or the area of the indentation using one of over 12 different test methods.

Automatic Surface Grinder

Quantity: 1 Set

Compared with other materials, aluminum alloy has many advantages, such as high strength and good corrosion resistance, which makes it widely used in civil and industrial fields, and has become the first choice of metal materials in the field of electronic and electrical, transportation and other fields.

The application status of aluminum alloy products

(1) Application of aluminum alloy in the field of transportation

Nowadays, the key issue in the field of social transportation is energy conservation and environmental protection, but choosing aluminum alloy is an effective way to achieve this goal. Therefore, since 1980, aluminum alloy materials have become the main materials in the transportation industry. At present, the use of aluminum alloy materials in the transportation industry has exceeded 25%, among which the use of aluminum alloy materials in the automobile industry has exceeded 15%, which has gradually become the largest field of aluminum alloy materials in the world.

Aluminum alloy has good impact resistance, vibration resistance, tensile resistance and other mechanical properties, so as to meet the relevant standards of materials selection for automobiles and high-speed trains. In addition, the compactness of aluminum alloy material is only that of steel material33%, which reduces the weight of the car itself, reduces driving resistance, and thus saves fuel consumption.

Moreover, aluminum alloy itself has better wear resistance and corrosion resistance, without rust removal, which greatly reduces the maintenance cost and manufacturing cost. What's more, compared with traditional steel, aluminum alloy is more convenient for recycling. Generally, the recovery value of an end-of-life car is  6 times as high as a steel car. Therefore, aluminum alloy is widely used in motorcycles, trains, high-speed rail, subway and other vehicle structural parts and air conditioning, as well as skin and armour plates of different types of yachts and cruisers. In recent years, with the continuous development of high-speed railway construction in China, all aluminium alloy structures are used in high-speed railway bodies. 6xxx series aluminium alloy with high strength is often selected for the body frame in the field of automobile materials.

(2) Application of aluminum alloy in the aerospace

In 1972, Alcoa successfully developed a new type of 7075 alloy by using Ti, Mn and other trace elements, and the application of aluminum alloy in Boeing 747 aircraft successfully opened the prelude of large-scale production of aluminum alloy in aircraft. At present, aluminum alloy has become the first material for spacecraft and aircraft lightweight. In civil aircraft structure, the aluminum alloy consumption is about 76%, for example, the aluminum alloy consumption of Airbus A380 is about 71%.

At present, almost all kinds of aluminum alloys in the market can be put into the aerospace field. becauseAl-Zn-Cu has high strength and good machinability, which is often applied to aircraft structural materials, such as stressed structural parts and frames, etc. Al-Li alloy is widely used in the manufacture of low-temperature fuel tanks for rockets and aircraft because of its low density and good low-temperature toughness.

(3) Application of aluminum alloy in the electronic and electrical field

Today,  there is about 6% of annually produced aluminum in the world are used in the field of electronics and electrics, while aluminum alloy is the main electronic conductor. After all, first of all, the price of aluminum alloy is far lower than that of copper alloy, which can strictly control the cost of laying cables. Secondly, because the compactness of aluminum alloy is lower than that of copper alloy, aluminum alloy can obtain the required conductivity on the basis of light and heavy, and significantly reduce the transportation cost. In addition, the recovery rate of copper alloy is lower than that of aluminum alloy, and it has high corrosion resistance, which can reduce the maintenance cost. At present, aluminium-clad steel cored aluminum strand is commonly used in high-voltage transmission lines. This type of aluminum alloy has the characteristics of high strength and good conductivity. There is also a great demand in the field of home appliances, computers and so on, especially the disk substrate of computers, packaging materials of home appliances and so on.

Future development trend of aluminum alloy products

With the development of science and technology and economic globalization, I believe that in the near future, aluminum alloy industry can get rapid development, and began to replace the position of steel, its development trend is mainly reflected in the following aspects.

(1) Optimize the production capacity structure, focus on corrosion resistance, financial, human and material resources and other products with better performance, so as to meet the needs of transportation, electrical packaging and aerospace fields.

(2) Develop aluminum matrix composites. Under the premise of the properties of the original alloy, many new aluminum matrix composites have better physical and mechanical properties, which is also the main way for future development and research.

(3) With the development and popularization of aluminum alloy comprehensive utilization technology, regeneration technology and recovery technology, the recovery rate is increasing.

(4) Innovate process equipment, improve production and processing methods, improve the production quality of aluminum alloy, and speed up production.

Please fill in the form below and our professionals will contact you within 12 hours!

After two months’ speedy production, aluminum die casting products for large orders of aluminum automotive parts have been shipped out successfully.

In addition, EMP has built a new warehouse to expand current warehousing capacity and better preserve goods before shipping.

The Transmission Housing is a load-bearing part. It is generally made of die cast aluminum alloy (Al-Si-Cu series alloy) through special molds. On the one hand, it has high strength, good pressure resistance, low hot brittleness, good mechanical properties and Machinability, and on the other hand, it has good castability and pressure resistance, which is suitable for manufacturing large-scale die castings with irregular shapes and more complex shapes.

Horizontal Milling Machine

Quantity: 1 Set

EMP is also equipped with an automatic cleaning line to ensure part quality and improve efficiency, and also save process costs.

With the rapid development of China's economy, especially the machining and cutting functions, the development of aluminum alloy die casting is becoming more and more mature. But the impact of heat treatment of aluminum alloy die-casting mold on product performance is also crucial.

1. Quenching cracking. The reasons for quenching cracks are generally due to improper design, overheating, decarburization, improper cooling, and poor quality of the mold steel.

2. Insufficient hardness. Generally, the lack of hardness of the die-casting mold is caused by the incorrect method of putting the mold parts into the cooling groove. Excessively high quenching temperature, excessive tampering, improper cooling, and decarburization are also causes of insufficient hardness.

3. Deformation exceeds the controllable range, mainly related to heat treatment.

4. Insufficient toughness. The reason for the lack of toughness may be that the quenching temperature is too high, and the holding time is too long to cause the grain coarsening, or because the tempering brittle zone is not avoided for tempering.

5. Grinding cracks. When there is a large amount of residual austenite in the mold parts, under the action of grinding heat, a tempering transition occurs, thereby generating tissue stress, which causes the mold parts to crack.

In order to provide a better service to our clients, EMP constructed many new workshops, including tooling maker, die casting, machining and inspection lines, etc. Let us show you around our new facilities.

X-Ray testing is the best nondestructive inspection method for detecting internal defects of castings can be examined to verify the internal structure and integrity of the specimen.The casting absorbs part of the radiation, and the remaining portion of the radiation exposes the radiographic film. Dense material withstands the radiation penetration, so the film is exposed to a lesser degree in those areas, giving the film a lighter appearance. Less dense materials allow more penetration and correlates to darker areas on the film. Any hole, crack or inclusion that is less dense than the casting alloy is revealed as a dark area.

Rocker Drilling Machine

Quantity: 1 Set

The application of die castings is widely used in all walks of life, and there is a huge demand in the market. However, during the production process, the problem of scratches on aluminum alloy die castings are easy to produce, and serious situations will cause scratches.

Reasons for the drag marks on aluminum alloy die castings:

1. The mold temperature is higher than 220 degrees, and castings are prone to scratches or sticky aluminum.

2. The iron composition of the aluminum alloy is less than 0.6%, and the aluminum material has an affinity with the mold, which causes the casting to be scratched or sticky.

3.  The ejection of the casting is not parallel, causing the casting to be pulled or deformed.

4.  The surface of the mold core is rough, resulting in a strain or rough surface of the casting.

5.  The draft angle of the casting core and wall is too small, which causes the casting to be scratched during the mould parting.

6. Insufficient spraying of the parting agents can also cause drag marks.

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A new factory had been established by EMP family. With the new factory, we can produce lots of high-quality aluminum castings. That means we will be more competitive in die casting industries and make our customers more satisfied.

EDM Line Cutter Equipment

Quantity: 1 Set

Aluminum metal and aluminum alloys have good fluidity and plasticity, but they tend to turn black during use. Why? The following are the reasons for the blackening of the surface of aluminum alloy die castings:

1. Unreasonable process design

The aluminum alloy die-casting parts are not handled properly after cleaning or pressure inspection, which creates conditions for the aluminum alloy die-casting parts to turn black and accelerate the generation of mildew.

2. Improper storage management

When the aluminum alloy die castings are stored at different heights in the warehouse, the moldy conditions are also different.

3. Internal factors of aluminum alloy

Many aluminum alloy die-casting manufacturers do not do any cleaning treatment after die-casting and machining processes, or simply flush with water, they cannot be thoroughly cleaned, and the surface of die-cast aluminum has corrosiveness such as mold release agent, cutting fluid, saponification fluid, etc. Substances and other stains, these stains accelerate the speed of black mold spots of aluminum alloy die castings.

4. External environmental factors of aluminum alloy

Aluminum is an active metal, which is easily oxidized to become black or mouldy under certain temperature and humidity conditions, which is determined by the characteristics of aluminum itself.

5. Selection of cleaning agent is not appropriate

The selected cleaning agent is highly corrosive, causing corrosion and oxidation of die-casting aluminum.