Refereed review article in scientific journal (A2)

Integration of Additive Fabrication with High-Pressure Die Casting for Quality Structural Castings of Aluminium Alloys; Optimising Energy Consumption

List of AuthorsAbhinav Anand, Devarajan Nagarajan, Mohamed El Mansori, Tharmalingam Sivarupan

PublisherTransactions of the Indian Institute of Metals


Publication year2023

Volume number76

Issue number2

Start page347

End page379




Traditional high-pressure die casting has several shortcomings in manufacturing defect-free castings with better casting yield. Selection of process parameters, improper process design, and poor thermal management of dies are the major factors contributing to the higher scrap rate and low casting quality, leading to increased energy consumption and carbon emissions. The optimal process parameters for casting operations and the required process design can be determined using simulation tools and experimental design techniques. The insertion of conformal cooling inserts fabricated via additive manufacturing can enhance the thermal management of dies, which will result in improved and uniform cooling of dies, better casting quality and die life. Furthermore, there is a significant potential for hybridising the additive and subtractive manufacturing methodologies to absorb the benefits of each manufacturing technique during the fabrication of die inserts of the conformal cooling channels. Hybrid manufacturing can resolve the shortcomings of additive manufacturing-built die inserts by enhancing the service life of the die components and reducing the scrap rate, thereby resulting in optimised energy consumption and cost. The emerging concept of “Smart Foundry” was recently initiated to resolve the challenges associated with the manufacturing industry, which aims to ease the production of high-precision parts. A new methodology termed “Convergent Manufacturing” has become the centre of attention for achieving the targets of Industry 4.0. The ongoing challenges faced by the high-pressure die-casting industries in achieving better energy management and the role of additive manufacturing and information technologies in defying those challenges are reviewed.

Last updated on 2023-06-06 at 12:04