High-Conductivity Copper Die Casting Parts for 5G and EV Chargers with Corrosion

Product Specification

Product description

• Density & Toughness: The grain structure solidified under pressure is refined, with a porosity controllable below 1%. Its strength and hardness are far superior to traditional cast parts, and its corrosion resistance and fatigue resistance are significantly enhanced;

• High Efficiency & Economy: Mechanized and automated production enables short-cycle mass manufacturing. Compared with processes like forging, the cost is reduced by more than 30%, the metal utilization rate reaches 95%, and waste materials can be 100% recycled and remelted;

• Flexible Customization: It can meet full-size requirements from micro thin-walled parts to extra-large structural components, supporting integrated molding of complex curved surfaces, ribs, threads, etc., and reducing subsequent assembly processes.

• Aluminum Alloy: As a widely used die-casting material, it has a density of only 2.7 g/cm³, which is 60% lighter than steel. Meanwhile, it possesses excellent corrosion resistance, superior electrical and thermal conductivity, and can be fully recycled and reused. In practical applications, it is often used in key components such as automobile engine blocks, 5G base station radiators, and high-speed rail seat frames. In terms of process, it is compatible with two mainstream methods—cold chamber die-casting and vacuum die-casting—capable of meeting different precision and performance requirements.

• Zinc Alloy: It is distinguished by good ductility and a smooth surface texture, capable of accurately forming thin-walled parts with a thickness of only 0.3 mm. Moreover, it causes less wear to molds during production, effectively extending the service life of molds. Leveraging these characteristics, zinc alloy die-cast parts are widely used in fields with high demands for appearance and precision, such as mobile phone rotating shafts, core components of smart door locks, and sanitary hardware accessories. In terms of process, hot chamber die-casting is mainly adopted, which offers higher production efficiency.

• Magnesium Alloy: It is an ideal choice for scenarios requiring lightweight properties, with a density as low as 1.8 g/cm³. While ensuring lightweight, it has an extremely high strength-to-weight ratio and excellent shock absorption performance, which can effectively buffer the impact of external vibration on components. Therefore, magnesium alloy die-cast parts are often used in products with strict requirements on weight and stability, such as UAV fuselages, satellite support structures, and medical CT machine brackets. In terms of process, it can be flexibly compatible with both hot chamber die-casting and cold chamber die-casting, adapting to different production scales and component specifications.

• Copper Alloy: Its core advantage lies in excellent electrical conductivity, with a conductivity of up to 85% IACS. At the same time, it has high toughness, capable of withstanding a certain degree of impact and wear, and possesses good corrosion resistance, enabling long-term stable operation in complex environments. Based on these properties, copper alloy die-cast parts are mainly used in scenarios with strict requirements on electrical conductivity and durability, such as new energy vehicle charging pile interfaces and core motor components, and are compatible with cold chamber die-casting in terms of process.

Note: Lead-tin alloy is only used in non-food contact scenarios, and is mostly used as an alloy additive to improve corrosion resistance.

• Dimensional Precision: Reaching IT8-IT11 grade, the tolerance can be controlled within ±0.1 mm, the minimum cast hole diameter is only 0.7 mm, and most products can be directly assembled without secondary processing;

• Surface Quality: After high-pressure filling and mold polishing, the surface finish can reach Ra1.6 μm, supporting subsequent surface strengthening treatments such as sandblasting and plating;

• Process Upgrading: Vacuum die-casting technology can be optionally adopted to reduce pore defects, increasing the fatigue life of components by 3-5 times; extra-large die-cast parts can realize the integrated integration of more than 70 parts through a die-casting machine of over 6,000 tons.

• New Energy Vehicles: Integrated die-cast body floor panels (e.g., Tesla Model Y solution), battery casings, and motor housings, achieving a dual improvement of 30%-50% weight reduction and sealing performance;

• Traditional Fuel Vehicles: Engine blocks, gearbox casings, and steering knuckles, further reducing fuel consumption by 8% through high-silicon aluminum alloy materials.

• High-Speed Rail Sector: Bogie gearbox casings and brake system components, meeting the EN 45545 fire protection standard and the requirements of high-frequency vibration working conditions;

• Aerospace Sector: Magnesium alloy UAV frames and satellite support structures, balancing lightweight and rigidity requirements.

• 5G & Consumer Electronics: Thin-walled die-cast radiators (with a wall thickness of 0.5 mm) and mobile phone middle frames, realizing efficient heat conduction and electromagnetic shielding;

• Industrial Equipment: Smart instrument casings and motor end covers, ensuring electrical conductivity and structural stability through copper alloy materials.