Experimental and industrial insights into distortion control for megacasting

Paper in proceeding, 2026

Megacasting enables the production of large, structurally integrated aluminum components for automotive applications, yet the geometrical distortion remains a major challenge. This study combines industrial observations, experimental trials, and literature analysis to identify and interpret key process parameters affecting distortion in high-pressure die casting of large components. The work integrates quantitative measurements from an industrial case study with qualitative input from experienced foundry engineers. The results highlight how die temperature distribution, cooling channel placement, solidification and cooling times, and quenching strategies influence residual stresses and distortion. Stress relaxation at elevated temperatures and constraint removal during ejection are highlighted as key mechanisms contributing to distortion formation. Building on these insights, potential approaches such as tool geometry correction and simulation-based prediction of distortion are discussed with respect to industrial feasibility. The findings contribute to improved understanding of distortion phenomena in megacasting and support future research toward predictive modeling and compensation strategies.