Magnesium-Aluminium Alloy Mould And Parts Processing Series

Leveraging our capabilities in semi-solid magnesium alloy forming, precision aluminum alloy die casting/machining, and magnesium-aluminum alloy mold manufacturing, we deliver high-reliability solutions from design to mass production for automotive, consumer electronics, medical, and industrial equipment.

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Three Core Process Platforms · Covering the Full Range of Magnesium/Aluminum Lightweighting Solutions

Centering on the development and mass production of lightweight, high-strength metal components, we have established three mature technology platforms: semi-solid magnesium alloy component processing (Thixomolding®), aluminum alloy component processing (high-pressure die casting/extrusion casting/five-axis precision machining), and magnesium-aluminum alloy mold processing. These capabilities respectively target “ultra-lightweight and high-precision forming,” “manufacturing of high-density, high-strength structural components,” and “ultra-long-life, ultra-precision mold assurance.” Together, they form an integrated solution spanning process principles, structural forming, mold longevity, and mass production delivery. This supports rapid introduction and stable, scaled production for clients in automotive, consumer electronics, medical, and industrial sectors.

Aluminum Alloy Component Processing

Establish comprehensive aluminum alloy capabilities spanning high-pressure die casting (HPDC), squeeze casting, and five-axis precision machining. Through mold filling simulation and digital production line control, achieve stable delivery of thin-walled, high-density structural components.

High-Pressure Die Casting for Thin-Wall Forming: 1600-ton clamping force equipment achieves wall thicknesses down to 0.5mm ± 0.1mm; MagmaSoft® filling optimization delivers fill rates exceeding 98%.

Extrusion Casting for High Density and Strength: Dual-pressure process achieves approximately 99.2% density, with tensile strength enhanced to 380 MPa—approximately 40% higher than conventional die casting.

Five-axis precision machining: Positioning accuracy ±0.01mm, surface finish Ra0.4μm, supporting aerospace-grade 1:30 aspect ratio thin-wall component machining.

Weight reduction and structural efficiency: Aluminum alloy density 2.7g/cm³, enabling approximately 35% component weight reduction; specific stiffness approximately 1.5 times that of steel.

Cost and Efficiency Advantages: Material utilization rate of approximately 92%, with machining hours reduced by about 50%.

Environmental and Surface Properties: Anodic oxide layer thickness of 20–25μm (MIL-A-8625), salt spray resistance exceeding 1000 hours.

Digital Mass Production Delivery: IoT-connected production line with OEE > 85%, CPK ≥ 1.67; monthly capacity of approximately 2 million units, with urgent orders delivered within 15 days.

Semi-Solid Magnesium Alloy Component Processing

Utilizing the Thixomolding® semi-solid thixotropic molding process, magnesium alloy is rapidly injected into the mold cavity in a solid-liquid coexisting state. This achieves a forming temperature approximately 30% lower than traditional die casting, resulting in finer grain structure and significantly reduced porosity and hot cracking defects. It is well-suited for the stable mass production of high-strength lightweight structural components.

Near-net-shape forming + high material utilization: Material utilization rate of approximately 95%, minimal machining allowance, and a reduction in unit cost of about 25% compared to traditional die casting.

Ultra-lightweight and mechanical properties: Yield strength ≥ 220MPa, elongation > 10%, specific strength 1.8 times that of aluminum alloy, enabling approximately 40% weight reduction in components.

Micron-Level Precision: Tolerances consistently maintained at ±0.05mm, surface roughness Ra≤0.8μm, enabling direct surface treatments like PVD.

Efficient Green Manufacturing: Energy consumption approximately 40% of traditional die casting (≤1.2kWh/kg), SF6-free fully enclosed production lines, reducing carbon footprint by about 60%.

High-Speed Mass Production: 90-second cycle time per part (including T5 heat treatment), supports 24/7 continuous operation, with annual single-line capacity of approximately 5 million units.

Global Compliance: Materials meet REACH/ASTM B94-17 requirements, with IMDS data available; online X-ray monitoring ensures CPK ≥ 1.67.

Magnesium-Aluminium Alloy Mould Processing

For high-corrosion/high-thermal-fatigue conditions in magnesium and aluminum alloy forming, a modular system integrating thermal management, coating reinforcement, ultra-precision manufacturing, and intelligent operation and maintenance has been developed. This significantly enhances service life, precision, and overall economic efficiency.

Thermal Management and Corrosion Resistance Breakthrough: Magnesium molds feature dual-circuit cooling channels, maintaining mold temperature fluctuations within ±3°C. Combined with HDS-5M special steel substrate and composite nitriding, mold life is extended to 120,000 shots (approximately double the industry average).

Aluminum Mold Nano-Coating Reinforcement: AlCrN+TiSiN nano-coating (hardness HRC85) boosts thermal fatigue resistance by 300%, extending service life to 180,000 shots.

Ultra-Precision Machining: Five-axis high-speed milling with positioning accuracy of ±0.01mm (aluminum molds)/±0.015mm (magnesium molds); surface roughness Ra 0.03–0.05μm, meeting mirror polishing requirements.

Micro Draft Angle Technology: 0.3° (magnesium)/0.5° (aluminum) micro-draft design pushes thin-wall molding boundaries.

Smart Operations & Maintenance: Embedded sensors monitor temperature/pressure/wear. AI predictive maintenance alerts achieve >95% accuracy, reducing downtime by approximately 30%.

Comprehensive Economics: Unit mold cost reduction of approximately 38–42%, with maintenance intervals extended to 50,000 (magnesium)/75,000 (aluminum) mold cycles.

Let’s Build the Next Lightweight Breakthrough Together.

Whether it’s mass production of structural components, precision mold development, or integrated material/DFM optimization, we provide full-process support from concept to delivery.