Progress in Integrated Die-Casting Technology for Aluminum Alloys

Abstract: In recent years, lightweight alloys, particularly aluminum alloys, have been widely adopted in the automotive industry, although research on large-scale, integrated, non-heat-treatable die-cast components remain limited. This review focuses on the research progress of non-heat-treatable aluminum alloys used in integrated die-cast components, with an emphasis on the composition design, current applications, and the influence of microstructure on the mechanical properties of Al-Si and Al-Mg alloy systems. It addresses the casting defects commonly encountered during the die-casting process, explores their impact on the mechanical properties, and proposes strategies for process optimization. Furthermore, this review innovatively discusses the latest advancements in die-casting technologies, including X-ray computed tomography (XCT), machine learning, and image processing. Ultimately, the critical challenges, technological advantages, typical applications, and sustainability concepts in the die-casting industry are summarized, and future development trends are explored, with the aim of driving the continued advancement of integrated die-casting technology.