The Electric Vehicle Reduction Gearbox Housing is a precision-engineered enclosure designed for single-speed reduction gearboxes used in battery electric vehicles (BEVs). As the EV industry accelerates toward lightweight structural components, Ningbo Ruican’s A356.2 aluminum alloy Investment Casting delivers the dimensional accuracy, thin-wall capability, and thermal management performance required by next-generation EV powertrains. Our integrated casting + CNC MACHINING process ensures that critical bearing seats, gear cavities, and mounting interfaces achieve tolerances as tight as ±0.02mm — essential for NVH (Noise, Vibration, Harshness) optimization in electric drivetrains.
Material Specifications
| Parameter | Specification |
|---|---|
| Material Grade | A356.2 (Al-Si7Mg) Aluminum Alloy |
| Tensile Strength | ≥ 228 MPa (T6 heat treated) |
| Yield Strength | ≥ 190 MPa |
| Elongation | ≥ 3% |
| Hardness | 75–105 HB |
| Heat Treatment | T6 (Solution + Artificial Aging) |
| Wall Thickness | 3.5–6.0 mm (thin-wall capability) |
| Dimensional Tolerance | CT6 (ISO 8062) |
| Weight Range | 3.0–12.0 kg |
Manufacturing Process
- Wax Pattern Injection: Aluminum die for wax patterns, wall thickness control at 3.5mm minimum
- Shell Building: 6–8 layer ceramic shell with specialized colloidal silica binder for aluminum
- Dewaxing & Firing: Flash dewaxing system, shell preheated to 700–800°C
- Pouring: A356.2 aluminum alloy poured at 710–730°C under controlled atmosphere
- Cooling: Controlled solidification with directional cooling for dendritic structure refinement
- T6 Heat Treatment: Solution at 540°C for 8–12 hours, quench, age at 155°C for 4–6 hours
- CNC Machining: 5-axis CNC for bearing bores (H6 tolerance), seal grooves, and mounting pads
- Leak Testing: Helium leak test at 2 bar pressure, acceptance ≤ 1×10⁻⁶ mbar·L/s
- Surface Treatment: Anodizing or e-coating per customer specification
Key Features
- Lightweight Design: A356.2 aluminum alloy reduces housing weight by 40–50% vs. cast iron equivalents, directly improving EV range
- Thin-Wall Casting: 3.5mm minimum wall thickness achieved through advanced shell technology and pouring optimization
- Thermal Management: Aluminum’s thermal conductivity (150 W/m·K) aids heat dissipation from reduction gears, extending lubricant life
- Precision Bearing Seats: CNC-machined to H6 tolerance (±0.01mm) for gear alignment, minimizing NVH in quiet EV operation
- Helium Leak Tested: 100% leak testing ensures oil-tight performance under thermal cycling from -40°C to 120°C
- IATF 16949 Compliant: Full APQP, PPAP, and MSA documentation available for automotive OEM qualification
Application Fields
- Battery Electric Vehicle (BEV) single-speed reduction gearboxes
- Plug-in Hybrid Electric Vehicle (PHEV) drive units
- Electric commercial vehicle (bus/truck) reduction gears
- Electric motorcycle and scooter gear housings
- EV all-wheel-drive disconnect housings
Why Choose Ningbo Ruican
Ningbo Ruican’s 17+ years of investment casting expertise, combined with IATF 16949 certification, positions us as a trusted partner for EV powertrain component manufacturing. Our A356.2 aluminum casting capability with thin-wall technology and 5-axis CNC precision meets the demanding requirements of global EV OEMs. We provide full PPAP Level 3 documentation, capability studies (Cpk ≥ 1.33), and design-for-manufacturing (DFM) support to accelerate your EV program timeline.
