De gevolgen van giettechnologie op de sector van nieuwe energievoertuigen

Lightweighting Demands Drive Material Innovation

The urgent need for extended range in new energy vehicles has propelled the casting industry toward lightweight materials. The application of aluminum alloy die-cast components in critical parts such as battery pack housings and motor brackets has significantly reduced vehicle weight. For instance, integrated die-casting technology achieves structural weight reduction by minimizing part count while enhancing body rigidity and safety. Additionally, magnesium alloy casting technology is increasingly applied to components like steering wheel frames, further optimizing overall weight distribution.

Process Innovations Enhance Core Component Performance

Motor Systems: High-precision cast iron components in motor housings optimize thermal management structures, boosting motor efficiency by approximately 15% while reducing thermal management energy consumption.

Battery System: The multi-chamber battery tray design, manufactured using aluminum alloy die casting, achieves lightweight construction while maintaining strength. It integrates liquid cooling channels, thereby improving thermal management efficiency.

Electronic Control System: As casting processes advance toward miniaturization, the heat sink for electronic control units has achieved a more compact flow channel design, increasing cooling efficiency by over 20%.

Technological Transformation Reshapes the Industry Landscape

Integrated Die-Casting Technology: Tesla’s pioneering integrated die-casting process consolidates over 70 traditional components into 1 or 2 large castings, boosting body manufacturing efficiency by 40% and driving breakthroughs in domestic die-casting machine tonnage toward the 10,000-ton range.

Digital Twin Technology: Virtual simulation optimizes casting process parameters, raising the first-pass yield rate for critical new energy vehicle castings from 85% to over 92%.

Green Manufacturing: Utilizing eco-friendly materials with over 60% recycled aluminum content, combined with waste heat recovery systems, reduces energy consumption per casting by 18%, aligning with the low-carbon philosophy across the entire lifecycle of new energy vehicles.

Future Trends

At the material level, high-strength aluminum alloys, magnesium alloys, and composite materials will accelerate the replacement of traditional cast iron to meet the new insulation requirements of 800V high-voltage platforms.

In process innovation, technologies like vacuum die casting and semi-solid forming will enhance precision in producing complex structural components.

Regarding industrial collaboration, foundries and battery manufacturers will establish joint laboratories to develop customized casting solutions for battery packs, potentially emerging as a new frontier for technological convergence.