Industry news
High-Conductivity Tool Steels for Low-Pressure and Semi-Solid Die Casting
In the current manufacturing landscape, precision aluminum forming technologies are facing both unprecedented opportunities and complex challenges. The automotive industry's shift towards electrification, coupled with the rise of "gigacasting," has generated exponential demand for large, high-integrity aluminum structural components. Low-pressure die casting (LPDC), with its advantages in smooth mold filling and suitability for complex geometries, remains a cornerstone process for producing high-quality aluminum components. Concurrently, semi-solid casting is gaining industrial traction as a complementary process, recognized for its capabilities in near-net shaping and producing components with exceptional integrity.
However, both LPDC and semi-solid casting are often constrained by a critical bottleneck: thermal management. Traditional die materials, such as H13 hot-work tool steel, have inherent limitations in thermal conductivity. This leads to severe thermal gradients within the die during operation, inducing thermal fatigue and premature failure. It also causes inconsistent solidification, triggering defects like shrinkage porosity that directly compromise yield. Conventional cooling channel designs are often restricted by material properties, preventing cooling lines from reaching critical hot spots and limiting efficiency.
This presentation explores a transformative solution: high-thermal-conductivity tool steels. Through industrial LPDC applications, we have observed significant process improvements. The high conductivity material rapidly extracts heat, reducing peak temperatures and homogenizing the thermal field. This mitigates thermal stresses, markedly extending die life. Accelerated heat transfer enables faster solidification, directly translating to shorter cycle times for high-volume production. Crucially, uniform temperature distribution reduces internal porosity, enhancing metallurgical quality and process repeatability while lowering scrap rates.
Building on these results, we extend our discussion to semi-solid die casting, which imposes even stricter demands on thermal performance. The narrow processing window of semi-solid slurries requires exceptional die responsiveness to maintain stable flow and precise filling. High-conductivity tool steels provide the thermal control necessary for these demanding fluidity requirements. Furthermore, they unlock new design freedom for cooling architectures. When combined with additive manufacturing, highly complex conformal cooling channels can be integrated, fully leveraging these materials to create next-generation die systems.
In summary, high-thermal-conductivity tool steels represent more than a material substitution; they are a powerful lever for advancing productivity, quality, and design innovation. This report details, with industrial case studies, how these materials overcome thermal challenges and empower the evolution of casting processes.
Brief Vita of the Speaker
Anwar Hameaux Hamasaiid
R&D Project Lead
ROVALMA S.A.
Dr. Anwar Hamasaiid is a recognised specialist in die technologies and die casting processes with a strong focus on improving productivity and casting quality. At ROVALMA, a global supplier of high-performance tool steels, he works on the development and industrial deployment of high thermal conductivity tool steels and advanced thermal management solutions for demanding applications, particularly in die casting. His expertise lies at the intersection of materials engineering and manufacturing, supporting Tier-1s and OEMs in reducing cycle time, enhancing process stability, and achieving consistent high-quality castings through optimised die materials and design.
Brief Abstract of the Presentation
Low-Pressure Die Casting (LPDC) remains a key manufacturing route for producing high-quality aluminium components in the era of electrification and giga casting. Semi-solid casting is increasingly regarded as a complementary high-potential process for manufacturing high integrity structural parts. However, productivity, scrap rate, and die durability are often constrained by thermal management limitations inherent to conventional die materials and traditional design approaches. This presentation draws on industrial LPDC applications employing high-thermal-conductivity tool steels, demonstrating significant reductions in cycle time, porosity, and thermal gradients, together with improved process stability and extended die service life.
Building on these results, the discussion is extended to next-generation semi-solid die casting, where narrower thermal processing windows and slurry fluidity control impose even higher demands on die thermal performance. The presentation highlights high thermal-conductivity tool steels as a primary lever for enhancing productivity and casting quality, while enabling greater design freedom in die and cooling architectures, including the integration of high-performance additively manufactured die components.
About Die Casting Congress
The 21st China Die Casting Congress will be held in Wuhan, China from March 25 to 27, 2026. Under the theme of "Al & Mg, Casting a Lighter Future", it will gather global industry leaders to jointly shape the lightweight future.
Register to be a delegate! Now!
Foundry Institution of Chinese Mechanical Engineering Society
Ms. You Yi
+86 24 25855793
youyi@foundrynations.com
Also organized by the Foundry Institution of Chinese Mechanical Engineering Society (FICMES), CHINA DIECASTING & CHINA NONFERROUS expo 2026, will be held from July 15 to 17, 2026 at Shanghai New International Expo Centre (Halls N1–N4). As Asia's largest specialized exhibition for die casting and nonferrous foundry, this edition, under the theme "Twin Engines: Al & Mg, A Lightweight Future," is expected to span 49,200 square meters, attract over 600 exhibitors, and welcome 28,000 professional visitors. Colleagues from around the world are warmly invited to visit and exchange insights.
However, both LPDC and semi-solid casting are often constrained by a critical bottleneck: thermal management. Traditional die materials, such as H13 hot-work tool steel, have inherent limitations in thermal conductivity. This leads to severe thermal gradients within the die during operation, inducing thermal fatigue and premature failure. It also causes inconsistent solidification, triggering defects like shrinkage porosity that directly compromise yield. Conventional cooling channel designs are often restricted by material properties, preventing cooling lines from reaching critical hot spots and limiting efficiency.
This presentation explores a transformative solution: high-thermal-conductivity tool steels. Through industrial LPDC applications, we have observed significant process improvements. The high conductivity material rapidly extracts heat, reducing peak temperatures and homogenizing the thermal field. This mitigates thermal stresses, markedly extending die life. Accelerated heat transfer enables faster solidification, directly translating to shorter cycle times for high-volume production. Crucially, uniform temperature distribution reduces internal porosity, enhancing metallurgical quality and process repeatability while lowering scrap rates.
Building on these results, we extend our discussion to semi-solid die casting, which imposes even stricter demands on thermal performance. The narrow processing window of semi-solid slurries requires exceptional die responsiveness to maintain stable flow and precise filling. High-conductivity tool steels provide the thermal control necessary for these demanding fluidity requirements. Furthermore, they unlock new design freedom for cooling architectures. When combined with additive manufacturing, highly complex conformal cooling channels can be integrated, fully leveraging these materials to create next-generation die systems.
In summary, high-thermal-conductivity tool steels represent more than a material substitution; they are a powerful lever for advancing productivity, quality, and design innovation. This report details, with industrial case studies, how these materials overcome thermal challenges and empower the evolution of casting processes.
Brief Vita of the Speaker
Anwar Hameaux Hamasaiid
R&D Project Lead
ROVALMA S.A.
Dr. Anwar Hamasaiid is a recognised specialist in die technologies and die casting processes with a strong focus on improving productivity and casting quality. At ROVALMA, a global supplier of high-performance tool steels, he works on the development and industrial deployment of high thermal conductivity tool steels and advanced thermal management solutions for demanding applications, particularly in die casting. His expertise lies at the intersection of materials engineering and manufacturing, supporting Tier-1s and OEMs in reducing cycle time, enhancing process stability, and achieving consistent high-quality castings through optimised die materials and design.
Brief Abstract of the Presentation
Low-Pressure Die Casting (LPDC) remains a key manufacturing route for producing high-quality aluminium components in the era of electrification and giga casting. Semi-solid casting is increasingly regarded as a complementary high-potential process for manufacturing high integrity structural parts. However, productivity, scrap rate, and die durability are often constrained by thermal management limitations inherent to conventional die materials and traditional design approaches. This presentation draws on industrial LPDC applications employing high-thermal-conductivity tool steels, demonstrating significant reductions in cycle time, porosity, and thermal gradients, together with improved process stability and extended die service life.
Building on these results, the discussion is extended to next-generation semi-solid die casting, where narrower thermal processing windows and slurry fluidity control impose even higher demands on die thermal performance. The presentation highlights high thermal-conductivity tool steels as a primary lever for enhancing productivity and casting quality, while enabling greater design freedom in die and cooling architectures, including the integration of high-performance additively manufactured die components.
About Die Casting Congress
The 21st China Die Casting Congress will be held in Wuhan, China from March 25 to 27, 2026. Under the theme of "Al & Mg, Casting a Lighter Future", it will gather global industry leaders to jointly shape the lightweight future.
Register to be a delegate! Now!
Foundry Institution of Chinese Mechanical Engineering Society
Ms. You Yi
+86 24 25855793
youyi@foundrynations.com
Also organized by the Foundry Institution of Chinese Mechanical Engineering Society (FICMES), CHINA DIECASTING & CHINA NONFERROUS expo 2026, will be held from July 15 to 17, 2026 at Shanghai New International Expo Centre (Halls N1–N4). As Asia's largest specialized exhibition for die casting and nonferrous foundry, this edition, under the theme "Twin Engines: Al & Mg, A Lightweight Future," is expected to span 49,200 square meters, attract over 600 exhibitors, and welcome 28,000 professional visitors. Colleagues from around the world are warmly invited to visit and exchange insights.
