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

Advances in Metal Casting Technology: A Review of State of the Art, Challenges and Trends—Part II: Technologies New and Revived

“…Since some of these have already been discussed, such as compound casting solutions, where complexity is introduced through an insert, the main focus of the present section will be on cores in general, as well as AM of lost and permanent molds. HPDC 3 Al HPDC process parameter adaptation to limit peak loads of cores, thus facilitating use of sand cores [161] HPDC 3 Al, Mg, Zn Use of sand cores with water-soluble binder and sealant for limited complexity undercuts and hollow sections [162] HPDC 3 Al, Mg, Zn Multi-plate die technology to optimize flow paths, thus facilitating increased part complexity [163] HPDC 3 Al, Mg Switch from conventional HPDC to semi-solid processing for increased flow paths and lower achievable wall thickness [164] GDC, LPDC, HPDC 3 diverse Implementation of improved heat conduction in dies through multi-material AM approaches [165] GDC, LPDC, HPDC 3 diverse Implementation of conformal cooling via AM of a die insert for HPDC of a Zn alloy [166,167] diverse diverse…”

“…Anand et al recently dedicated an extensive review to this topic, which specifically stresses the benefits of conformal cooling for energy consumption, which is achieved directly by improving thermal management, as well as indirectly via superior process control. As a result, fewer scraps need to be remelted [167]. In both the conformal cooling and the heat spreading scenarios, laser-based AM processes profit from an extensive development history, which, over time, has covered most materials that are relevant for the manufacturing of permanent molds and dies.…”

“…In cases where even higher productivity is required, wire arc additive Manufacturing (WAAM) may be considered as an alternative to laser-based technologies [205]. Achieving the required surface finish may require a hybrid manufacturing approach, combining additive with subtractive manufacturing both in the case of powder-and wire-based processes [167]. While all these technologies are available, their application in series production remains limited.…”

Thermal post-treatment and material characterization of laser powder bed fusion additively manufactured Ti-6Al-4V

“…Moreover, the high cost of manufacturing, longer lead time and suboptimal use of raw materials are major barriers to traditional manufacturing routes. Additive manufacturing (AM) solves these issues and produces parts with complex geometries that are difficult to achieve through conventional routes, along with design freedom for specific end-use applications [2,3]. Laser powder bed fusion (PBF-LB) is the most used AM process for this purpose.…”