Call Us 
Send me an inquiry
Monday - Friday
Can Integrated Body be Realized by Casting?
You are here: Home » News » PRODUCTS NEWS » Can Integrated Body be Realized by Casting?

Can Integrated Body be Realized by Casting?

Views: 22     Author: Site Editor     Publish Time: 2018-11-07      Origin: Site

Q:Can automobiles be made integral body-frames by casting?

This is a very interesting question.Most people's first reaction must be negative. This reminds me of an engineer who once said that the mobile phone shell could not be made with CNC and was overturned by Apple.The answer is still uncertain.

For the current situation of the automobile industry, there are the following problems:

1.Why is the production of car body mainly based on stamping and welding?

2. Are there any other production methods for body parts besides stamping?

3. Can we make an integrated body?


1. Why is the production of car body mainly based on stamping and welding?

The production mode is mainly determined by the product performance requirements, quality requirements, production efficiency and production costs.

Nowadays, the typical body structure is composed of the surface panels and the body frame. The surface panels are determined by the shape. Those familiar shapes are stamped by the panels. In order to meet the requirements of safety, NVH and other performance requirements, and at the same time reduce the weight as much as possible, the body frame is mainly composed of a beam structure with a hollow closed interface.

The outer panels are thin plates, and the beam structure is also composed of thin plates. The most convenient and fast way to make sheet metal parts is stamping, and the dimension precision of stamped parts is also very good. In the technology of connecting steel plates, welding is the most mature and efficient. At present, stamping and welding production has achieved a high degree of automation, more than 90% of the work can be done by robots.

Simply, the current production mode of stamping and welding can well meet the quality requirements of vehicle performance, size accuracy and other requirements, but also can produce dozens of cars in an hour to meet the production requirements, the price is not expensive, naturally become the first choice.


2. Are there any other production methods for body parts besides stamping?

In fact, a small part of the high-end car body has been cast, advanced casting technology has been able to cast thin-walled parts with complex shapes and used in mass production.

The following picture shows the front wheel cover of Cadillac ATS, which is manufactured by high pressure casting aluminium technology.

The casting parts are 30% - 40% lighter than the stamping tailor-welded parts with the same properties due to the advantages of variable thickness, reinforced ribs and more complex shape than stamping, and the number of parts is greatly reduced.

In addition to casting, a large number of composite materials have been used in the production of automobile body, some of which are produced by injection moulding, which is similar to casting.


3. Can we make an integrated body?

Now the common car body is assembled by hundreds of small parts through welding. In fact, the assembly workshop and consumers can treat the car body as a whole part, which should be the largest part of the car. If the collision is severe, it must be cut and repaired by tailor welding.

The body structure of some high-end vehicles with carbon fibre body can really be called monolithic body or monocoque, the most famous of which is Lamborghini. Carbon fibre body has been developed unremittingly since 30 years ago, which was absolutely science and technology at that time.

According to the performance requirements, different materials and processing methods should be adopted in different areas. Through such a single cabin, the weight of the vehicle can be reduced and the safety performance can be improved.


With the development of technology, the products using integral body are no longer the high-end toys that can not be reached. It may be popularized to the mainstream market at any time.



  • What is 'multiple certification'?

    This is where a batch of steel meets more than one specification or grade. It is a way of allowing melting shops to produce stainless steel more efficiently by restricting the number of different types of steel. The chemical composition and mechanical properties of the steel can meet more than one grade within the same standard or across a number of standards. This also allows stockholders to minimise stock levels.

    For example, it is common for 1.4401 and 1.4404 (316 and 316L) to be dual certified - that is the carbon content is less than 0.030%. Steel certified to both European and US standards is also common.

  • What surface finishes are available on stainless steels?

    There are many different types of surface finish on stainless steel. Some of these originate from the mill but many are applied later during processing, for example polished, brushed, blasted, etched and coloured finishes.

    The importance of surface finish in determining the corrosion resistance of the stainless steel surface cannot be overemphasised. A rough surface finish can effectively lower the corrosion resistance to that of a lower grade of stainless steel.

  • Can I use stainless steel at high temperatures?

    Various types of stainless steel are used across the whole temperature range from ambient to 1100 deg C. The choice of grade depends on several factors:

    1. Maximum temperature of operation
    2. Time at temperature, cyclic nature of process
    3. Type of atmosphere, oxidising , reducing, sulphidising, carburising.
    4. Strength requirement

    In the European standards, a distinction is made between stainless steels and heat-resisting steels. However, this distinction is often blurred and it is useful to consider them as one range of steels.

    Increasing amounts of Chromium and silicon impart greater oxidation resistance. Increasing amounts of Nickel impart greater carburisation resistance.

  • Can I use stainless steel at low temperatures?

    Austenitic stainless steels are extensively used for service down to as low as liquid helium temperature (-269 deg C). This is largely due to the lack of a clearly defined transition from ductile to brittle fracture in impact toughness testing.

    Toughness is measured by impacting a small sample with a swinging hammer. The distance which the hammer swings after impact is a measure of the toughness. The shorter the distance, the tougher the steel as the energy of the hammer is absorbed by the sample. Toughness is measured in Joules (J). Minimum values of toughness are specified for different applications. A value of 40 J is regarded as reasonable for most service conditions.

    Steels with ferritic or martensitic structures show a sudden change from ductile (safe) to brittle (unsafe) fracture over a small temperature difference. Even the best of these steels show this behaviour at temperatures higher than -100 deg C and in many cases only just below zero.

    In contrast austenitic steels only show a gradual fall in the impact toughness value and are still well above 100 J at -196 deg C.

    Another factor in affecting the choice of steel at low temperature is the ability to resist transformation from austenite to martensite. 

  • Is stainless steel non-magnetic?

    It is commonly stated that “stainless steel is non-magnetic”. This is not strictly true and the real situation is rather more complicated. The degree of magnetic response or magnetic permeability is derived from the microstructure of the steel. A totally non-magnetic material has a relative magnetic permeability of 1. Austenitic structures are totally non-magnetic and so a 100% austenitic stainless steel would have a permeability of 1. In practice this is not achieved. There is always a small amount of ferrite and/or martensite in the steel and so permeability values are always above 1. Typical values for standard austenitic stainless steels can be in the order of 1.05 – 1.1. 

    It is possible for the magnetic permeability of austenitic steels to be changed during processing. For example, cold work and welding are liable to increase the amount of martensite and ferrite respectively in the steel. A familiar example is in a stainless steel sink where the flat drainer has little magnetic response whereas the pressed bowl has a higher response due to the formation of martensite particularly in the corners.

    In practical terms, austenitic stainless steels are used for “non-magnetic” applications, for example magnetic resonance imaging (MRI). In these cases, it is often necessary to agree a maximum magnetic permeability between customer and supplier. It can be as low as 1.004.

    Martensitic, ferritic, duplex and precipitation hardening steels are magnetic.

Tel: +0086-574-89017168-8007
Room2503,Tower A, Trade Centre of Ningbo,Tiantong South Road No.588,Yinzhou District,Ningbo
COPYRIGHT © Ningbo Yinzhou FUCHUN Precision casting CO.,LTD