Developing innovative casting technologies

• Overview 
• Skills and experience
• Implementation
• Facilities
• Partnerships

Overview

Casting is a shape forming process that allows parts of a complex shape to be made without relying on other processes such as joining or welding. 

The process is used for generating components in many industries, mostly for the automotive industry. 

Low-cost and high-productivity are factors that make casting a very competitive process for the manufacturing industry. 

CSIRO has been involved in casting research and development for more than 30 years, working in collaboration with private enterprise.

During this time, we have developed numerous casting and tooling technologies and are industry leaders in die-casting. 

We have developed a specialised capability in light metal (aluminium and magnesium) casting research and development as part of the Light Metals Flagship program.

Skills and experience

The specific areas of expertise in the field include:

• high pressure, low pressure and gravity casting techniques
• casting processes (sand-, semisolid-, squeeze-, remelt ingot, continuous casting)
• die-casting processes (specialising in runner and gating systems, machine injection and control systems)
• computer simulation and modelling (for die filling, solidification and stress-distortion in all casting processes)
• casting defect prediction and diagnosis
• process control and optimisation
• surface modification and coatings
• mechanical property testing
• tooling and die design
• cast bonding.

Implementation

CSIRO casting technologies capability aims to develop innovative or improved casting and related processes, products and materials to increase productivity and competitiveness. 

Achievements that have contributed to CSIRO’s casting expertise include the development of:

• T-Mag: high-yield magnesium die casting process
• low cost production of magnesium sheet using twin roll casting technology
• Advanced Thixotropic Metallurgy (ATM): breakthrough technology for high-pressure die-casting
• CASTcoat™ (in partnership with the Cooperative Research Centre (CRC) for Cast Metals Manufacturing): long-life die coat for low-pressure and gravity die-casting
• a new heat-treatment process for strengthening aluminium components.

Facilities

CSIRO’s casting research facilities are extensive and include:

• hot and cold chamber high-pressure die-casting machines
• low pressure and squeeze casting machines
• gravity die casting machine
• horizontal continuous direct chill caster and a twin roll caster, both for magnesium casting
• ingot casting machine
• mechanical testing and metallography laboratories
• X-ray and optical analytical systems
• casting process computer simulation and modelling packages.

Partnerships

CSIRO is a member of the CRC for Cast Metals Manufacturing (CAST), a collaborative initiative involving:

• Australian government research agencies
• several universities
• smelting companies
• manufacturers
• die-casting companies. 

CSIRO also undertakes collaborative work with the Victorian Centre for Advanced Materials Manufacturing (VCAMM).

Learn more about CSIRO’s work in Metal Processing.

• CASTcoat™ is a trademark of CSIRO Australia.

Contact Information

Primary Contact

Location

Related Links

• Light Metals Flagship
• Metal Processing
• CSIRO Materials Science and Engineering
• CRC for Cast Metals Manufacturing (CAST) [external link]
• Victorian Centre for Advanced Materials Manufacturing (VCAMM) [external link]

• Light Metals Flagship overview
• Cool tool for cheaper metal
• New technology for casting magnesium automotive components
• Heat treatment of high-pressure die-castings
• Ready to roll
• Clever coating for die casting
• Creating and processing light metals
• Aluminium and magnesium manufacturing