How to Achieve Synergistic Development between the Foundry Industry and the New Energy Sector

There is a close and profound connection between the new energy industry and the foundry industry, especially in terms of technological upgrading, market demand, and industrial transformation. The rapid development of the new energy industry is profoundly reshaping the landscape of the foundry industry, driving it towards lightweight, integrated, and high-end directions.

I. New Energy Vehicle Drive Casting Technology Innovation

Integrated casting has become a mainstream trend. Tesla was the first to propose the body one-piece forming casting technology, which uses a super-large casting machine to cast dozens or even hundreds of parts that originally needed to be stamped and welded in one go, significantly reducing processes, costs and improving efficiency. The domestic NIO ET5 has become the first mass-produced integrated casting model, and other automakers such as XPeng, BYD and FAW are also accelerating their layout. This technology requires the use of 6,000-ton or even 16,000-ton class casting machines, promoting the localization process of high-end casting equipment.

Lightweight materials are widely used. To alleviate the range pressure caused by battery weight increase in electric vehicles, the demand for aluminum alloy, magnesium alloy and other lightweight alloy castings has soared. Compared with traditional steel, aluminum alloy castings can significantly reduce weight and have become the preferred material for electric drive housings, battery trays and structural parts in new energy vehicles. FAW Casting and Forging has achieved the trial production of magnesium alloy electric drive housings and flywheel housings, reducing weight by 5% to 10% compared with aluminum alloys.

Functional integrated parts drive process upgrades. Modern battery trays not only need to support the structure but also integrate functions such as liquid cooling channels and sensor brackets, prompting the casting process to shift from single casting to a “casting + machining + welding” composite process, and products are developing towards high thermal conductivity, high strength and complex structures.

II. Wind Power and Energy Storage Expand Casting Application Scenarios

Large-scale wind power castings are in high demand. Large components such as hubs, bases and main shafts in wind power equipment require high-strength and corrosion-resistant castings, which are widely used in harsh environments such as offshore wind power. With the trend of large-scale wind power, the requirements for casting size and performance are constantly increasing.

Energy storage systems create new demands. Energy storage battery housings need to ensure sealing and safety through precision casting, driving casting enterprises to enter the new energy supporting field.

III. Policy and Industrial Chain Synergy Accelerate Transformation

The state has issued the “Guiding Opinions on Promoting the High-Quality Development of the Foundry and Forging Industry”, clearly stating that by 2025, advanced processes such as integrated casting and lightweight high-strength alloys will be industrialized, and by 2035, the industry as a whole will enter the international advanced ranks. Cities such as Zhaoqing and Changchun are building new energy vehicle and casting industrial clusters, forming an “automobile – three electric – casting” coordinated development industrial ecosystem.

In addition, 3D printing sand mold technology has been applied by BMW, Toyota and others in engine and integrated body casting, significantly shortening the R&D cycle and reducing mold costs, facilitating rapid iteration. The development of heat-treatment-free aluminum alloys has also solved the problem of large thin-walled castings being unable to be heat-treated, improving the yield rate.