Course detail

Pressure die casting technology

FSI-PDCAcad. year: 2026/2027

The course focuses on comprehensive knowledge acquisition in die casting technology, used to produce castings from non-ferrous metals and alloys. Students will gain insights ranging from the basic theoretical principles and applications of this technology, through the identification of its limitations and benefits, to practical aspects of foundry production.

The course covers knowledge of casting die design, die casting machine operating modes, gating system sizing, and mold venting. Students will become familiar with the construction of die casting machines, requirements for material properties and heat treatment of molds, as well as control systems and measurement of process parameters on these machines.

An important component of the course is mastering the operation of die casting machines, including the use of robotic workstations, and methods of non-destructive testing (NDT) of castings made from aluminum, magnesium, and zinc alloys.

As part of the practical exercises, students will participate in excursions to observe modern die casting machines, control systems, and technologies for producing complex-shaped castings, particularly for the automotive and electrical industries. The course also includes a semester project, in which students will design the production technology for a selected casting, including the design of the gating system and venting.

Language of instruction

Czech

Number of ECTS credits

3

Mode of study

Not applicable.

Guarantor

doc. Ing. Vladimír Krutiš, Ph.D.

Department

Institute of Manufacturing Technology (ÚST)

Entry knowledge

It is assumed that students have knowledge acquired during previous studies, particularly in the following areas: materials science and engineering, fundamentals of design and technical drawing, foundry technologies, metrology, and statistics.

Rules for evaluation and completion of the course

The conditions for obtaining credit include active participation in exercises and the completion of a semester project. The course examination consists of both written and oral parts. After the written preparation, the student will demonstrate their knowledge during the oral exam.

Student grading follows the ECTS grading scale:

  • A – Excellent (90–100 points)

  • B – Very Good (80–89 points)

  • C – Good (70–79 points)

  • D – Satisfactory (60–69 points)

  • E – Sufficient (50–59 points)

  • F – Fail (0–49 points)

Attendance at lectures is recommended. Participation in exercises is one of the conditions for obtaining credit. In the case of an excused absence, the instructor may determine an appropriate method of compensation.

Aims

The objective of the course is the application of knowledge in the fields of manufacturing technologies, materials science, machine and equipment design, material testing methods, process control and product quality, and metrology, as applied to the production of castings using die casting technologies. Students will acquire knowledge and skills in the basic design of such molds, selection of foundry technologies for die-cast aluminum, magnesium, and zinc alloys, application of numerical simulations in die casting technology, and understanding the construction of die casting machines, their control and measurement systems, and evaluation of technological parameters, including their statistical assessment. A further specific objective of the course is to teach students to understand the principles and procedures for production planning and control, as well as quality management of die-cast products.

Study aids

The materials will be accessible through e-learning.

Prerequisites and corequisites

Not applicable.

Basic literature

CAMPBELL, John. 2: The new metallurgy of cast metals. Amsterdam: Elsevier Butterworth-Heinemann, 2003, 337 s. ISBN 0-7506-4790-6.
ROUČKA, Jaromír. Metalurgie neželezných slitin. Brno: Akademické nakladatelství CERM, 2004, 148 s. ISBN 80-214-275 (CS)
VINARCIK, E. J. High Integrity Die Casting Processes. 2002 ISBN 9780471275466 (EN)

Recommended reading

WALKINGTON, William G. Die casting defects. Resemont, Il.: NADCA, 1997. (EN)

Classification of course in study plans

  • Programme N-SLE-P Master's 2 year of study, winter semester, compulsory

Type of course unit

 

Lecture

26 hod., optionally

Teacher / Lecturer

doc. Ing. Vladimír Krutiš, Ph.D.

Syllabus

  1. Pressure die casting technology – fundamentals, classification of high-pressure and low-pressure casting methods
  2. Design of machines for low-pressure and high-pressure casting, die casting machines with hot and cold chambers
  3. Periphery of the casting workplace
  4. Mold design, PQ diagrams, clamping force
  5. Concept of gating systems and venting
  6. Die thermal loading, metal die materials, and their heat treatment
  7. Temperature control, internal and external die cooling, die fatique
  8. Technological and process parameters of casting machines, their measurement, archiving, and evaluation
  9. Castability of die-cast parts, allowances, and optimization approaches
  10. Melting and melting units, holding furnaces, dosing
  11. Causes of defects in die-castings and their elimination, casting quality. NDT inspection of defects
  12. Special die-casting technologies – Reocasting, Thixocasting, Squeeze casting
  13. Mega/Gigacasting technology

Laboratory exercise

13 hod., compulsory

Teacher / Lecturer

doc. Ing. Vladimír Krutiš, Ph.D.

Syllabus

  1. Definition and assignment of the semester project
  2. Examples of design solutions for die casting machines
  3. Layout of the casting workplace
  4. Application of PQ diagrams, calculation of the machine clamping force
  5. Excursion 1 – visit to a die casting foundry
  6. Calculation of the gating system, casting time, and system cross-sections
  7. Numerical simulation – examples of calculations on real castings
  8. Project Trend results – smart mold
  9. Presentations by HPDC technology suppliers
  10. Use of VR in HPDC technology
  11. Excursion 2 – visit to a die casting foundry
  12. Presentation of the semester project
  13. Presentation of the semester project