According to the China Aluminum Network, approximately 10% of global primary aluminum and 85% of recycled aluminum are used in the production of aluminum alloy castings. In 2010, the total output of aluminum and aluminum alloy casting products worldwide reached 22 million tons, with die castings accounting for over 60%, while low-pressure and sand castings each made up around 20%. The industry has maintained an annual growth rate of about 10%. In China, the output of aluminum alloy casting products has reached 2.8 million tons, with die castings taking more than 55% of the market, low-pressure castings at around 25%, and sand castings at approximately 20%. Other foundry products make up about 3%, with an impressive annual growth rate of up to 15%.
Aluminum alloy castings and die castings are primarily used in transportation equipment such as cars and motorcycles, followed by electronics, home appliances, and hardware. Recently, they have also gained widespread use in aerospace, aviation, and mechanical manufacturing. Globally, annual vehicle production is around 70 million units, with over 800 million vehicles on the road. In 2010, China’s auto production surpassed 18 million, and the number of vehicles exceeded 80 million. On average, developed countries use about 200 kg of aluminum per vehicle, with some reaching up to 380 kg, while China is moving toward 150 kg. If aluminum alloy castings account for 75% of the automotive aluminum content, the demand for these products would be enormous. It's safe to say that the development of the automobile industry is the main driver behind the growth of aluminum alloy casting. With the rapid advancement of modern vehicles like cars and motorcycles, the potential for aluminum alloy casting products is vast.
Over the past few decades, cast aluminum alloys have closely aligned with the needs of the modern transportation industry. Extensive research has been conducted to develop high-strength, high-toughness, wear-resistant, low-shrinkage, weldable, and corrosion-resistant aluminum alloys with good fluidity for casting and die-casting applications. These materials are essential for components such as engine blocks, pistons, cylinder heads, and wheels.
In recent years, with the sustained economic growth and the rapid development of modern transportation, aerospace, and electromechanical industries, the demand for aluminum alloy castings has surged, along with higher quality requirements. For example, aluminum is now widely used in both cars and motorcycles. Currently, the world requires over 300 million aluminum wheels, and China has a production capacity of 150 million annually. Aluminum alloy vehicles are gradually being introduced from motorcycles to cars, medium-sized, and heavy-duty vehicles, which places even higher demands on the composition and performance of cast and die-cast aluminum alloys.
Many developed countries have developed numerous new aluminum alloys tailored for different applications. For instance, in 1994, the German Rhine Aluminum Company introduced Sila0llt-36, a high-strength, high-toughness, high-pressure die-cast aluminum alloy that is now widely used in the automotive industry. A year later, the company launched M-resistant 59, a high-pressure die-cast alloy with excellent mechanical properties and high toughness in its as-cast state. This alloy offers unique advantages for structural and suspension system parts, where heat treatment is not feasible. In 2004, Rhinestone Aluminum Company developed another alloy called Castasil-37, known for its strong resistance to aging and wide application in areas requiring long-term stable performance.
Additionally, research into new cast and die-cast aluminum alloys containing rare earth elements, as well as fiber- or particle-reinforced cylinder and piston cast aluminum alloys, has shown promising results. These innovations continue to expand the possibilities for aluminum alloy applications across various industries.
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