Calculating Aluminium HPDC parts cost requires consideration of several factors.
Including raw material costs, tooling costs, energy consumption in the production process, labor costs, and other overheads.
Raw material cost
The material cost of aluminum alloy is an important part of the cost of HPDC parts.
According to the evidence, the price of aluminum is approximately $1,900 per tonne.
Meanwhile,prices may vary depending on the supplier.
Tooling costs
HPDC molds are one of the most important assets in the high-pressure die casting process, and their cost can range from a few thousand dollars to millions of dollars, depending on the size, material, and complexity of the mold.
Although the initial investment cost of the mold is higher, it can be amortized through multiple uses.
Energy consumption
Electricity is the main source of energy consumption in the production of aluminum alloys.
For example, electrolytic aluminum consumes about 13,500 kWh of electricity per tonne.
In the HPDC process, high pressure and rapid cooling also increase energy consumption, but the overall efficiency is higher.
Labor costs
Labor costs include the wages and maintenance expenses of the operators.
Based on evidence, the labor cost per pound of parts is about $0.12.
Other overheads
Include equipment depreciation, repair costs, and additional costs due to porosity defects, etc.
Defects that may arise in the HPDC process (e.g., porosity, cold sealing, etc.) require additional treatment, which increases costs.
Productivity
The HPDC process has a high production efficiency and can produce hundreds of parts per hour, which reduces the fixed cost per unit of product.
Comprehensive Costing
Let’s assume a typical HPDC part weighs 20 pounds, has a mold life of 300,000 injection cycles, and a mold cost of $100,000.
If the price per pound of aluminum is averaged at 27 yuan (about 4 US dollars), the raw material cost is 468 US dollars. Labor costs are $24 ($0.12 per pound).
Let’s assume that the mold depreciation and maintenance expense is 10% of the mold cost, which is 10% of $100,000, or $10,000.
Application of aluminum alloy in HPDC production
Aluminum alloy is a common HPDC alloy, which is widely used in structural components such as auto parts and engine components.
It is widely used in the die casting process due to its excellent flowability, especially for the production of complex designs and thin-walled components.
Mechanical properties
Aluminum alloys have good mechanical properties, including yield strength, tensile strength, and elongation, making them able to withstand deformation and stress.
These properties make it ideal for manufacturing components that require high strength and corrosion resistance.
Productivity
HPDC technology is very popular in the automotive industry due to its ability to improve overall consumption efficiency by reducing vehicle weight.
Innovations in HPDC technology, such as computer-aided design and simulation integration, have increased production speed and accuracy, reducing costs.
Cost-effectiveness
Although HPDC technology is significantly cost-effective in large-scale production, its initial investment is high.
Due to its good mechanical properties and fluidity, aluminum alloy shows high cost performance in HPDC production.
High productivity
HPDC technology enables the rapid production of large numbers of parts, which helps to reduce unit production costs.
Excellent mechanical properties
The high strength and corrosion resistance of aluminum alloys make them excellent in the high-pressure die casting process, which reduces the cost of subsequent processing and maintenance.
Wide range of applications
The wide range of applications of aluminum alloys in several industries indicates their economics in HPDC production.
