A passenger car contains roughly three to four thousand fasteners. The difficulty in automotive is not any single part but the combination of multiple vibration sources, large temperature gradients, fast assembly cycle times and high volumes. Zhenhua has supplied automotive and machinery customers since 1993 and holds TS16949 certification.
Chassis and suspension → DIN 25201 Wedge Lock Washers
Chassis and suspension are safety-critical and take continuous road vibration and impact. Wedge lock washers replace conventional spring washers under strong vibration, preventing the rattle and wear that follow loosening. Dacromet is recommended (no hydrogen embrittlement, suitable for high-strength safety parts).
Exhaust systems → DIN 6796 Belleville Washers / DIN 9250 L Belleville Washers
Exhaust manifolds, catalytic converters and silencers exceed 600 C with frequent thermal cycling, and the thermal expansion mismatch between bolt and flange is significant. Belleville washers act as elastic elements to compensate thermal displacement and maintain preload through high-temperature cycling. Stainless material recommended.
Engine and transmission ancillaries → DIN 6798A Tooth Lock / DIN 7967 All-Metal Lock Nuts
Engine ancillaries vibrate at high frequency and sit close to heat sources. Tooth lock washers handle locking, paired with all-metal lock nuts to avoid nylon components failing at high temperature.
Aluminium body → Custom Stamped Parts
Lightweighting means aluminium is increasingly used in bodies, but aluminium has low yield strength and dents easily under fastening load. The solution is a flat washer with a larger bearing area to distribute pressure. Zhenhua can produce custom outer diameters and thicknesses.
Body exterior and lamps → Screw Cup Washers / Countersunk Washers
Exposed fastening points require good appearance. Screw cup washers with their curved bearing face give good protection when used with self-tapping screws; countersunk safety washers sit flush for body exterior and lamp fixing.
Interior, harness and clips → DIN 6798J Internal Tooth / Starlock Washers
Interior and harness fixing is a light-load application but cost sensitive, and requires grounding continuity. Starlock and shaft retaining washers are push-on designs needing no turning, suited to fast production line takt times and particularly to clip and positioning structures.
PPAP documentation at the required level can be provided, including dimensional reports, material certification and process capability studies.
Provide drawings, material, annual volume and quality requirements, and we will assess feasibility and quote with a development timeline.
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