Robustness Assessment in the Optimization of Low-Pressure Die Casting Subject to Variations in Secondary Alloy Composition

Porosity is a significant factor affecting the final mechanical properties in aluminum casting. Therefore, minimizing porosity by optimizing the casting parameters is of great importance. However, during normal production, some variability must be considered for these parameters, especially when usi...

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Published inInternational journal of metalcasting Vol. 19; no. 5; pp. 2864 - 2880
Main Authors Vergnano, Alberto, Rezvanpour, Hamed, Spessotto, Marvin, Leali, Francesco
Format Journal Article
LanguageEnglish
Published Cham Springer International Publishing 01.09.2025
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ISSN1939-5981
2163-3193
2163-3193
DOI10.1007/s40962-024-01504-4

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Abstract Porosity is a significant factor affecting the final mechanical properties in aluminum casting. Therefore, minimizing porosity by optimizing the casting parameters is of great importance. However, during normal production, some variability must be considered for these parameters, especially when using secondary alloys. Variations in alloy composition can greatly influence the solidification process, microstructure, and the product’s mechanical properties. Accordingly, achieving a robust design that accounts for secondary alloy composition variations is crucial to ensure the consistent quality and performance of the cast parts. This research uses a car wheel as a case study for a low-pressure die casting process. An optimization process is then conducted using a genetic algorithm (GA) to refine casting parameters such as heat transfer coefficient (HTC) and initial pouring temperature. Finally, the results are analyzed using the signal-to-noise ratio and the Taguchi quality loss function method to measure the robustness of the design sets. These results indicated that by conducting an optimization process and introducing noise factors as parameters, a robust design that withstand alloy variations can be achieved, and a design of simulation experiment can be established.
AbstractList Porosity is a significant factor affecting the final mechanical properties in aluminum casting. Therefore, minimizing porosity by optimizing the casting parameters is of great importance. However, during normal production, some variability must be considered for these parameters, especially when using secondary alloys. Variations in alloy composition can greatly influence the solidification process, microstructure, and the product’s mechanical properties. Accordingly, achieving a robust design that accounts for secondary alloy composition variations is crucial to ensure the consistent quality and performance of the cast parts. This research uses a car wheel as a case study for a low-pressure die casting process. An optimization process is then conducted using a genetic algorithm (GA) to refine casting parameters such as heat transfer coefficient (HTC) and initial pouring temperature. Finally, the results are analyzed using the signal-to-noise ratio and the Taguchi quality loss function method to measure the robustness of the design sets. These results indicated that by conducting an optimization process and introducing noise factors as parameters, a robust design that withstand alloy variations can be achieved, and a design of simulation experiment can be established.
Author Leali, Francesco
Spessotto, Marvin
Vergnano, Alberto
Rezvanpour, Hamed
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Issue 5
Keywords secondary alloys
genetic algorithm
aluminum casting
design of simulation experiments
optimization
porosity
low-pressure die casting
mechanical properties
Taguchi method
Language English
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Chemistry and Materials Science
Materials Science
Metallic Materials
Structural Materials
Technical Paper
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Title Robustness Assessment in the Optimization of Low-Pressure Die Casting Subject to Variations in Secondary Alloy Composition
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