Aluminum Die Casting Motor End Cover
KYLT provides mold manufacturing and die-casting production for aluminum alloy die-casting motor end covers. The motor components produced are widely used in new energy vehicles, industrial motors, household appliances, and other fields, achieving lightweight, high-strength, and high-efficiency mass production.
1. Material Selection
- Alloy Specifications:
- ADC12 (JIS H5302): Preferred for high fluidity and complex geometry filling.
- ZL101A (GB/T 1173-2013): Equivalent to A356 (ASTM B85), used for higher mechanical strength applications.
- Chemical Composition (ZL101A): Si 6.5–7.5%, Mg 0.25–0.45%, Ti 0.08–0.20%, Fe ≤0.2%, Cu ≤0.1%, Zn ≤0.1%, Mn ≤0.1%, total impurities ≤0.7% (balance Al).
- Mechanical Properties (T6 condition): Tensile strength ≥295 MPa, elongation ≥4%, hardness 60–80 HB.
2. Mold Design & Construction
- Mold Material: H13 hot-work tool steel, hardened to 48–52 HRC.
- Critical Design Features:
- Draft angle: 0.5°–2° (to prevent sticking).
- Radii: Minimum 1 mm at corners to reduce stress concentration.
- Venting System: Vent grooves depth ≤0.1 mm; located at last-fill zones.
- Core Pulls: Required for side holes or undercuts (e.g., mounting boss recesses).
3. Die Casting Process Parameters
| Parameter |
Optimal Range |
Notes |
| Melting Temperature |
650–680°C (ADC12) |
Avoid exceeding 700°C to minimize oxidation |
| Mold Preheat Temperature |
150–200°C |
Maintain working temp at 200–250°C |
| Slow Shot Speed |
≤0.3 m/s |
Prevents air entrainment |
| Fast Shot Speed |
2–5 m/s |
Ensures complete cavity filling |
| Hold Pressure |
70–100 MPa |
Duration: 1.5–2 s per mm of wall thickness |
| Cooling Rate |
10–20°C/s |
Influences grain size and mechanical properties |
4. Gating & Overflow System Design
- Gating Type: “Y”-comb or side-runner system to minimize turbulence.
- Overflow Pockets: Placed at last-fill zones to trap oxides and entrapped gas.
- Special Case: For motor end covers with central thermal nodes, tilt-casting + side riser design improves gravity feeding and reduces shrinkage porosity.
5. Post-Processing & Quality Control
- CNC Machining:
- Precision boring of bearing bores (tolerance: ±0.02 mm).
- Surface flatness of mounting faces: ≤0.05 mm.
- Surface Treatment Options:
- Electrostatic coating (for corrosion resistance).
- Anodizing (Type II, 10–20 µm thickness).
6. Common Defects & Mitigation Strategies
| Defect |
Root Cause |
Corrective Action |
| Porosity |
Poor degassing, high melt temperature |
Use vacuum die casting; degas melt at 450°C for 15 min |
| Shrinkage Cavities |
Inadequate feeding |
Optimize riser size/location; increase hold pressure time |
| Flash |
Insufficient clamping force, mold wear |
Increase clamping force; inspect and regrind parting lines weekly |
| Surface Streaks |
Mold release agent residue |
Reduce spray volume; use water-based, low-silicone agents |
| Post-Machining Porosity Exposure |
Shallow subsurface voids |
Adjust gate location; increase filtration during melt handling |
KYLT offers free quotation services for aluminum alloy die-casting motor end covers, motor housings (casing), and cooling fan blades etc.: cnkylt@aliyun.com
