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Aluminum Casting Technologies

Aluminum Casting Technologies and Cost efficiency


Aluminum is the recognized metal of choice for the production of lightweight elements in the vehicle, aerospace, and transportation industries. Casting liquid aluminum alloys into metal molds utilizing processes such as gravity, low pressure, and high pressure die casting is an effective expense means of producing complicated shapes that need minimal machining. Australia's automobile industry supports a strong regional aluminum die casting industry, producing parts that consist of automobile transmission real estates, cylinder heads, inlet manifolds, and engine sumps.



Development in world vehicle markets for aluminum die-cast components is developing significant opportunities and difficulties for the Australian industry, placing itself as a global gamer. Through collaborations between our research organizations and key automotive individuals such as Nissan and Ford, CAST has developed ingenious and unique innovations that have benefited our partner's productivity. In turn, these technologies have generated IP that is poised on the brink of commercialization. An example included is CASTcoat, a project that started as postgraduate research at CSIRO and The University of Queensland. It was established further under CAST project funding at CSIRO with industrial trials at Nissan, Ford, Merne Products, Castalloy, and others. Now it is a provisionally patented technology.

Cycle Time Reduction.

  • Automated Fault Diagnosis in Aluminium Die Casting.

  • Modeling of Fluid Flow Inside a Die Cavity Utilizing Smoothed Particle Hydrodynamics.

  • Integrated Gravity Die Design Methodology.

  • In the HPDC Process, gain a reduction in Metal Pressure.

  • For LPDC and GDC, tailoring of CAST's New Die Coat.

  • Improved Quality Aluminium Automotive Castings.

  • Cycle Time Reduction.

To boost the productivity of high-pressure die casting by decreasing casting machine cycle time by 30%.


More than a 20% decrease in cycle time has been achieved and executed on selected parts at two industry partner plants. The task has involved:

  • Recognizing opportunities to decrease the process cycle time.

  • Carrying out a research study to show the principle.

  • Bringing out the actual trial to show the theoretical findings.

This demanded the involvement of shopfloor personnel in order to execute changes to the procedure. Often such trials conflict with the day-by-day production of parts, and just through genuine cooperation has it been possible to accomplish the job objectives.


This project's third year has shown the advancement of genuine cooperation between scientists and commercial partners. The current research study findings gotten through modeling and simulation have been carried out on the shopfloor with the support of personnel from Ford and Nissan. Once trialed during a production duration, the modifications have been implemented as part of the procedure, hence providing continuous expense advantages through a decrease in the time required to produce each component.