Advances in Metal Casting Technology: A Review of State of the Art, Challenges and Trends—Part I: Changing Markets, Changing Products

Abstract

Metal casting is among the oldest primary shaping processes known to humanity [...]

Thick Film Sensor Manufacturing Techniques for Realization of Smart Components via Low Pressure Die Casting

“…Besides, in case of insufficient bonding between insert and casting, the former may act as a wound within the component, and thus limit its performance [15] [16]. While one potential remedy is the reduction of sensor and thus insert size as proposed earlier by Lang et al [15], supporting the formation of a tight bond is another: The latter approach has been discussed in several studies on Al-Al compound cast components [17]. However, a direct transfer to sensor integration is still pending.…”

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

“…Special cases among such wrought alloys are those that are not primarily selected for structural properties but rather for functional properties like thermal or electrical conductivity. Here, a link to e-mobility applications, as discussed in Part I of this work, is apparent, e.g., in rotor casting [1]. Classical rotor aluminum Al99.7 is almost pure and characterized by limited castability; nevertheless, it is employed in HPDC to produce electrical engine components [55].…”

“…The casting industry has experienced its share of such effects, and in as far as they concern changing markets and boundary conditions, these have already been discussed in the preceding Part I of this text. The delimitation between both these parts is illustrated in Figure 1, which has also been included in a similar form in Part I [1].…”

“…Having said this, what is the motivation behind devoting a section of this text to compound and hybrid casting technologies? In the preceding Part I of this Editorial, Gigacasting [62,63] was presented as one approach toward the realization of large structural castings for automotive applications [1]. There are, however, alternatives to this technique which may succeed in eliminating some of the drawbacks of the former approach.…”

“…The present text is the second part of an editorial written for a Special Issue entitled Advances in Metal Casting Technology. The first part, which was published in November 2022, contains an overview of the global metal casting industry and highlights specific aspects that have led to changes in markets and products, such as e-mobility, the associated advent of Gigacasting technology, or the increasing pressure on the casting industry to justify and minimize the environmental impact of its processes [1]. This second part assumes a different perspective by examining the technological developments within the industry that can either be seen as general trends or as responses to the preceding challenges; in other words, this text discusses technologies both new and revived.…”