A Comprehensive Study on Pressure Die Casting: Process Mechanisms, Material Science, Challenges, and Future Trends

Authors

  • S. B. Pulate Department of Mechanical Engineering, Padmashri Dr. Vithhalrao Vikhe Patil Institute of Technology and Engineering (Polytechnic), Loni, Maharashtra, India Author
  • S. D. Shelke Department of Mechanical Engineering, Padmashri Dr. Vithhalrao Vikhe Patil Institute of Technology and Engineering (Polytechnic), Loni, Maharashtra, India Author
  • R.H. Narvade Department of Mechanical Engineering, Padmashri Dr. Vithhalrao Vikhe Patil Institute of Technology and Engineering (Polytechnic), Loni, Maharashtra, India Author
  • V.R. Lawande Department of Mechanical Engineering, Padmashri Dr. Vithhalrao Vikhe Patil Institute of Technology and Engineering (Polytechnic), Loni, Maharashtra, India Author

DOI:

https://doi.org/10.32628/IJSRSET251256

Keywords:

Pressure Die Casting, Hot Chamber Die Casting, Cold Chamber Die Casting, Defects in Pressure Die Casting

Abstract

Pressure Die Casting (PDC) remains a cornerstone in the mass production of complex metal components, particularly in automotive, aerospace, and electronics industries. This paper presents an in-depth analysis of the PDC process, covering fundamental mechanisms, die and alloy selection, heat transfer dynamics, defects and their mitigation, and recent innovations. The paper also discusses the integration of computational modeling, sustainability considerations, and the emergence of hybrid manufacturing systems. Through literature review and industrial case analysis, this study provides a holistic view of the current state and future directions of pressure die casting technology.

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References

Jones, M., & Patel, R. (2022). Simulation in Die Casting. International Journal of Manufacturing Science.

Wang, H., et al. (2021). Vacuum-Assisted Die Casting for Automotive Components. Journal of Material Processing.

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Bockus, S., & Gailus, R. (2022). Advances in metal casting technology: A review of state of the art, challenges and trends—Part I: Changing markets, changing products. Metals, 12(11), 1959. https://doi.org/10.3390/met12111959

Envicura. (2023). High pressure die casting (HPDC): Process, benefits, and applications. Retrieved from https://envicura.com/high-pressure-die-casting-hpdc-process-benefits-and-applications/

Schilling, R., & Beckermann, C. (2015). High-pressure die-casting: Contradictions and challenges. ResearchGate. https://www.researchgate.net/publication/273058978_High-Pressure_Die-Casting_Contradictions_and_Challenges

Makhlouf, M. M., & Guthy, H. V. (2001). Review of new process technologies in the aluminum die-casting industry. Advanced Materials and Processes, 159(5), 41–45. https://doi.org/10.1081/AMP-100108624

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Published

26-05-2025

Issue

Vol. 12 No. 3 (2025): May-June

Section

Research Articles

License

Copyright (c) 2025 International Journal of Scientific Research in Science, Engineering and Technology

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

How to Cite

[1]
S. B. Pulate, S. D. Shelke, R.H. Narvade, and V.R. Lawande, “A Comprehensive Study on Pressure Die Casting: Process Mechanisms, Material Science, Challenges, and Future Trends”, Int J Sci Res Sci Eng Technol, vol. 12, no. 3, pp. 414–420, May 2025, doi: 10.32628/IJSRSET251256.

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