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HPDC ARCHITECTUREDOL ACTIVEIATF 16949:2016

Aluminium Die Cast Components & Market Applications

Thin-walled aluminium components cast on our 250T & 350T cold-chamber HPDC cells in Chennai, finished and machined in-house, and supplied to OEM and Tier-1 assembly lines.

Cell Tonnage
250T – 350T
Alloys
5 grades
Metrology
CMM verified
01 // Industries Served

Components by Industry

  • SECTOR 01

    Automotive Powertrain & Chassis

    Critical lightweight structural nodes, engine mounts, powertrain brackets, and precision steering rack housings capable of dynamic cyclical load.

    • ADC12
    • AlSi9Cu3
    • Low-Porosity Design
  • SECTOR 02

    Electric Motors & E-Mobility

    Thin-walled stator housings with integrated cooling channels, rotor end-rings, and hermetically sealed IP67 battery enclosure sub-assemblies.

    • Thermal Path
    • A380
    • Leak-Tested
  • SECTOR 03

    Medical & Diagnostic Hardware

    Ultra-smooth sanitary device chassis, internal centrifuge mounts, and radiation-shielded diagnostic housings with non-magnetic alloy purity.

    • AlSi10Mg
    • Ra 0.8 Surface
    • Clean Surface
  • SECTOR 04

    Machine & Equipment Construction

    Structural vibration-damped flanges, industrial gearbox end-shields, pneumatic manifold blocks, and hydraulic pump housings rated for 250+ bar.

    • LM24
    • 250+ Bar Rated
    • High Tensile
  • SECTOR 05

    Agricultural Implements & Tractors

    Robust irrigation pump heads, power take-off (PTO) bearing carriers, sprayer meter housings, and tractor transmission auxiliary brackets.

    • Corrosion Guard
    • ADC12
    • High Yield
  • SECTOR 06

    Industrial Power & Renewable Energy

    Solar inverter heat sink chassis with fin profiles down to 1.8mm pitch, grid switchgear covers, and offshore wind power transmission housings.

    • AlSi9Cu3
    • High Thermal Conductivity
    • Anodized Ready
02 // Typical Components

Examples of Custom OEM Castings

Representative part types we cast and machine to customer drawings. Images are illustrative; tolerances and tests are agreed per part.

  • TYPICAL COMPONENTDOL LEVEL A
    Aluminium die cast electric motor housing with integrated cooling jacket
    Thin-wall housing

    EV Stator Cooling Jacket

    Motor housing with an integrated cooling jacket for electric traction motors. Thin walls and a sealed coolant path make leak testing part of the process.

    Alloy Spec:
    AlSi10Mg (High Ductility)
    Critical tolerance:
    [INSERT ACHIEVED TOLERANCE]
    Leak test:
    [INSERT TEST SPEC]
    Typical cell:
    [INSERT CELL USED]
  • TYPICAL COMPONENTPPM < 10
    Aluminium die cast powertrain mounting bracket
    Structural bracket

    Dual-Axis Powertrain Mount

    Ribbed structural bracket that replaces a multi-piece steel fabrication. Mounting bosses are cast in and machined to position.

    Alloy Spec:
    ADC12 / JIS H2118
    Critical tolerance:
    [INSERT ACHIEVED TOLERANCE]
    Machined features:
    Mounting bores
    Typical cell:
    [INSERT CELL USED]
  • TYPICAL COMPONENTHIGH PRESSURE
    Aluminium die cast hydraulic manifold end-flange with machined ports
    Pressure-tight part

    Hydraulic Manifold End-Flange

    End-flange for hydraulic equipment with machined ports and an O-ring sealing face. Impregnation can be specified for pressure tightness.

    Alloy Spec:
    A380 / LM24 Hybrid
    Flatness:
    [INSERT ACHIEVED FLATNESS]
    Leak test:
    [INSERT TEST SPEC]
    Typical cell:
    [INSERT CELL USED]
03 // Alloy Properties

Aluminium Die Casting Alloys We Use

TYPICAL VALUES FOR DIE CAST TEST BARS · MELT CHEMISTRY SPECTROMETER-VERIFIED

Aluminium Die Casting Alloys We Use: chemistry and mechanical properties
Alloy DesignationKey Chemistry (%)Tensile (MPa)Yield (MPa)Elongation (%)Thermal (W/m·K)Primary Application
ADC12 (JIS)Si 9.6-12.0 / Cu 1.5-3.5310 MPa150 MPa2.5%96 W/m·KAutomotive Brackets, Gearcases
A380 (ASTM)Si 7.5-9.5 / Cu 3.0-4.0330 MPa160 MPa3.0%100 W/m·KGeneral Electronic Housings
AlSi9Cu3 (EN)Si 8.0-11.0 / Cu 2.0-4.0320 MPa155 MPa2.0%110 W/m·KHigh Thermal Heat Sinks
AlSi10MgSi 9.0-11.0 / Mg 0.2-0.5300 MPa175 MPa5.0%130 W/m·KThin-walled Stators & Medical
LM24 (BS)Si 7.5-9.5 / Cu 3.0-4.0280 MPa150 MPa1.5%98 W/m·KHydraulic Flanges, Heavy Ag

How these components are made

DFM REVIEW WITH EVERY QUOTE

Send your 3D model for a die casting quote

Upload STEP/IGES or 2D drawings. Our engineers review castability, gating and machining before issuing a tooling and part-price quotation.

Submit 3D Drawings md@sunmaxcasting.in