Development of an Innovative Low Pressure Die Casting Process for Aluminum Powertrain and Structural Components

Abstract

An innovative Low Pressure Die Casting (LPDC) process has been developed for aluminum cast components based on the application of an extra pressure during the solidification process. The new process, named “Low Pressure Squeeze Casting” (LPSC) has been proved to be able to increase the solidification rate, refining the microstructure of the casting, and reducing its shrinkage porosity. Furthermore, the cycle time is also reduced, increasing the productivity of the process. Two demonstrators from the automotive and wind power industries have been produced to validate the process in a relevant industrial environment.