Integrated die casting: low cost and high efficiency to realize automobile lightweight. We believe that the most significant change brought about by integrated die casting for automobile production process is to give consideration to lightweight and cost reduction, greatly shorten production time, easy recycling of materials and environmental protection.
Why Tesla is so optimistic about integrated die casting. At the Tesla battery day press conference on September 22, 2020, musk said that Tesla Model y will use integrated die-casting to produce the rear underbody
The weight of sector assembly and lower body assembly will be reduced by 30% and the manufacturing cost will be reduced by 40%. At the same time, Tesla plans to splice three large die castings into the whole lower body assembly to replace the original 370 parts. Finally, the total weight of the vehicle can be reduced by 10% and the mileage can be increased by 14%.
We believe that the characteristics of integrated die casting are high production efficiency and low cost. Take the rear floor of Tesla modely as an example. In terms of efficiency, integrated die casting reduces more than 70 parts of the rear base sector of model 3 to 1-2. Compared with the 2 hours required for stamping and welding of more than 70 parts, integrated die casting greatly reduces the time to 80-90 seconds. Therefore, musk said that the Texas factory can achieve an annual output of 500000 model y, which is fully benefited from integrated die casting. In terms of cost, one-piece die casting mainly reduces the manufacturing cost through the saving of a large number of processes and equipment. The one-time die casting with a large die casting saves the traditional stamping and welding processes of dozens of parts, saves a lot of production equipment, and reduces the floor area by 30%. The manpower needed for skilled workers is only one tenth of that of traditional automobile welding factories. Musk said that a large die casting can save 300 Siasun Robot&Automation Co.Ltd(300024) .
Market space calculation: every 10 million vehicles drive the demand of 100 billion yuan of die-casting materials and 30 billion yuan of die-casting machines. The value of single vehicle is expected to increase from 2800 yuan to 7200 yuan to 10000 yuan. Every 10 million vehicles is a market space of 28 billion, 72 billion and 100 billion. In terms of penetration rate of integrated die-casting for automobiles: new energy vehicles are expected to adopt integrated die-casting technology in a wide range, and fuel vehicles also have the power of low-cost energy conservation and emission reduction. According to the roadmap of energy saving and new energy vehicle technology issued by the Ministry of industry and information technology, the goal of lightweight single vehicle aluminum in China is to achieve 250kg / vehicle and 350kg / vehicle in 2025 and 2030 respectively. According to the statistics of CM group, China’s single car aluminum consumption in 2021 is only 145kg, and there is a long way to go to achieve the goal of single car aluminum consumption. The integrated die casting provides a low-cost and lightweight way for fuel vehicles.
Industrial chain investment combing: die casting machine + die casting factory + heat-free alloy. Chinese die-casting manufacturers and die-casting machine equipment are actively arranging the integrated die-casting business. Lijin technology first broke through the super large die-casting machine, realized the production of 6000 tons of die-casting machine in 19 years, and successfully supplied 9000 tons of die-casting machine in April of 22 years. At present, 12000 tons of die-casting machine is being developed and Tesla has been successfully supplied.
In terms of upstream heat-free alloy, Lizhong Sitong Light Alloys Group Co.Ltd(300428) successfully developed and mass produced, breaking the foreign monopoly. Die casting alloy with high elongation and no heat treatment is also the key technology of integrated die casting. China also has a positive layout of heat-free alloys. Lizhong Sitong Light Alloys Group Co.Ltd(300428) has successfully developed heat-free alloy and successfully mass produced, breaking the foreign monopoly. In terms of performance, on the basis of ensuring the high strength of the material, the elongation is more than 5 times higher than that of traditional die-casting materials. At the same time, the price of similar materials is lower than that of foreign companies, and the content of mo-7 is only 15% – 15% in the process of deterioration, which solves the unique deterioration problem of similar materials.
Risk tip: uncertainty in the process of new technology substitution.
