This product is the core component of diesel engine power transmission - front gear housing cover, using high-pressure die-casting aluminum alloy process of one-piece molding, designed for medium and heavy-duty diesel engines with high strength and high reliability needs. The product integrates multiple functions such as timing gear system sealing, oil channel guidance, sensor mounting and structural support, etc. It meets the stringent sealing requirements while realizing significant light weight. The precise structural design can effectively carry gear loads and isolate external shocks, guaranteeing accurate timing and smooth power output of the Common Rail fuel injection system, providing robust and efficient drive train protection for commercial vehicles, construction machinery and marine diesel engines.
Technical Parameters
| parameter term | Technical indicators |
|---|---|
| casting pressure | 80-130 MPa (high pressure die casting, real time closed loop control) |
| Mold temperature control | 180-280℃ (multi-point temperature control, accuracy ±5℃) |
| material grade | ADC12 / EN AC-46000 / Al-Si9Cu3(Fe) / As per customer's specification |
| tensile strength | ≥240 MPa (die-cast state) |
| yield strength | ≥160 MPa |
| elongation | ≥1.2% |
| durometer | ≥85 HBW |
| Operating Temperature Range | -40°C to +150°C (up to 175°C instantaneously) |
| Dimensional accuracy | Class CT6 (ISO 8062 up to CT5 for bearing bores and locating pin bores) |
| Flatness Requirements | Installation bonding surface ≤0.08mm/100mm |
| surface treatment | Passivated/sprayed/painted/bare machined surfaces (optional) |
| Sealing requirements | Leak rate ≤ 0.2 mL/min @ 300kPa (Helium Mass Spectrometry Detection/Dry Gas Tightness Detection) |
| fatigue life | ≥1×10? cycles (simulating full engine load conditions) |
Quality Assurance System
Certified Endorsement:
- Conforms to IATF 16949 quality management system standards for the automotive industry
- ISO 9001 Quality Management System Certification
- ISO 14001 Environmental Management System Certification
Process Control:
- Closed-loop monitoring of the entire die casting process: injection speed profile, boost build-up time, specific compaction time feedback
- Aluminum liquid metallurgy quality control: spectrochemical composition analysis, gas content density testing, metamorphic effect assessment
- Intelligent regulation of mold temperature: dynamic heat balance control, reducing the tendency of shrinkage and loosening.
- Automatic optimization of release spraying: ensuring smooth release of complex deep-cavity structures
Testing Standards:
- 100% Coordinate InspectionKey mating surfaces, bearing holes, locating pin holes accuracy ≤ 0.05mm
- X-ray non-destructive testing: Internal porosity, shrinkage, and cold segregation determined to be in accordance with ASTM E505 Class 2 standards
- 100% Gas Tightness Test: Simulates the actual working pressure and automatically determines the leakage rate
- ultrasonic flaw detection: Screening for internal defects in critical stress areas
- Metallographic Organization Inspection: Eutectic silicon morphology, iron phase compound control to ensure fatigue performance
- Cleanliness testing: Particle size and quantity control to meet engine lubrication system requirements
application scenario
Diesel engines for heavy commercial vehicles
Suitable for 6L-13L displacement heavy-duty diesel engine, applied to logistics tractor, dump truck, mixer truck and other scenarios. High-pressure die-casting aluminum alloy structure reduces weight by 40%~50% compared with cast iron, which effectively reduces the fuel consumption of the whole vehicle, and at the same time meets the structural stability and sealing reliability under high burst pressure.
Off-road diesel engines
Widely used in construction machinery (excavators, loaders, bulldozers), agricultural machinery (tractors, combine harvesters) and industrial equipment with diesel engines. Excellent anti-vibration and fatigue performance ensures long-term reliable operation under adverse working conditions, and anti-corrosion surface treatment adapts to the outdoor all-weather operating environment.
Marine Diesel Engine
Used in medium and high speed marine propulsion main engine and power generation auxiliary engine, ADC12 material has good salt spray corrosion resistance after passivation treatment, together with the strict air tightness requirements, to ensure the long-term stable operation of ship power system in the marine environment.
Diesel units for power generation
Suitable for fixed and emergency diesel generator sets. High-precision machining ensures smooth operation of the gear train, reduces mechanical noise, and excellent heat dissipation performance helps to control the cabin temperature, ensuring the reliability of continuous power supply.
Specialty Vehicle Power Systems
Applied to military tactical vehicles, armored vehicles and other high-performance diesel engines. Passed the severe vibration and shock test to meet the military standard environmental adaptability requirements, lightweight design helps to improve vehicle mobility and payload.
Technical Highlights
Topology optimization of high-strength structures
Based on the finite element analysis and the real load spectrum of the diesel engine, the structure is optimized for the high burst pressure and gear transmission impact. The key stress area adopts reinforcement and variable cross-section design, which improves the overall stiffness by more than 30% while reducing the weight by 12%~15%, and effectively suppresses the transmission of gear meshing vibration.
Highly dense vacuum die casting process
Adopting vacuum-assisted die-casting technology, the vacuum degree of the mold cavity can reach below 90mbar, which significantly reduces the defects of rolled gas. With local extrusion technology, solve the problem of shrinkage in thick parts, casting density enhancement, to meet the ≤ 0.2mL/min harsh sealing requirements, without the need for infiltration treatment.
Integrated Functional Consolidation Design
The timing pin hole, oil nozzle mount, crankshaft position sensor hole, high-pressure oil pump drive window, oil/gas separator interface and other features are molded by one-piece casting. This reduces the number of parts and secondary processing procedures, and improves assembly efficiency and reliability.
Directional cooling and heat balance control
Optimized cooling waterway layout for the characteristics of high heat load of diesel engine ensures that the gear housing cover maintains a uniform temperature field under full engine operating conditions. The optional integrated oil cooling channel design further enhances the heat dissipation efficiency and ensures the reliability of the gear train and sensors.
Precision Bearing Hole Processing Technology
The bearing holes of the gear housing cover adopt roughness and precision composite boring process, with roundness ≤ 0.01mm and cylindricity ≤ 0.012mm, which ensures precise alignment of the timing gear system, reduces the meshing noise, and enhances the transmission efficiency and service life.
Whole life cycle corrosion protection system
Develop multi-level protection program for diesel engines with high humidity and heat, high salt spray and high chemical corrosion working environment. Base passivation treatment + powder coating, pass neutral salt spray test ≥ 480 hours, meet the full life cycle of the engine anti-corrosion needs.
Advantages compared to gasoline engine gear housing cover
| comparison dimension | Diesel Engine Gear Housing Cover | Gasoline engine gear housing cover |
|---|---|---|
| structural rigidity | Higher (30% increase in reinforcement density) | standard design |
| Sealing Pressure Requirements | ≥300kPa test pressure | Normally ≤200kPa |
| Anti-fatigue design | Considering high voltage impulse loads | Conventional cyclic loads |
| Wall thickness design | Partially thickened (to withstand higher burst pressure) | Extreme thin-wall |
| Thermal Requirements | Higher (high diesel heat load) | Standard Heat Dissipation |
| Corrosion resistance requirements | Tougher (multiple conditions for commercial vehicles) | General Requirements |
| NVH Control | Focus on gear knocking noise | Focus on valve train noise |
