Leveraging Statistical Analysis Software in Advancing Material Efficiency

Improved Results in Pore Die Casting Using Statistical Methods

• Material Savings: Achieved up to 13% reduction in component weight while maintaining acceptable surface quality.
• Uniform Porosity: Controlled and homogeneous pore distribution ensures consistent quality and efficient resource use.
• Optimized Parameters: Precise control of casting factors, such as piston speed and press residue, ensures reliable and repeatable results.
• Statistical Accuracy: Cornerstone software facilitated effective planning, detailed statistical analysis, and clear identification of optimal casting conditions.

The Pore Die Casting Process

Pore die casting introduces controlled porosity into components, effectively reducing aluminum usage without compromising the overall quality or functionality of cast parts. By managing porosity distribution strategically, this process achieves material efficiency and weight reduction, especially suited for components with lower stability requirements.

Cornerstone’s Role in Optimizing Casting Parameters with Statistical Analysis

Cornerstone software played an essential role in systematically planning and analyzing the experiments discussed in this research. Utilizing a statistical method known as D-optimal experimental design, Cornerstone identified key casting parameters—such as piston speed and press residue—that directly influenced component quality, weight, and porosity. By optimizing these factors, the experiments demonstrated up to 13% weight reduction while maintaining satisfactory surface quality.

Key Parameters Analyzed

• Piston Speed: Adjustments in piston movement significantly influence porosity distribution.
• Press Residue: Optimal settings help minimize excess material while maintaining good surface integrity and structural integrity.
  
  

Results Supported by Cornerstone Software

• Reduction of component weight by up to 13%, without causing significant deterioration in surface quality.
• Cornerstone software facilitated systematic analysis of factors and their interactions, ensuring robust conclusions and reproducible results.

Learn more about Cornerstone software capabilities and how it can enhance your process efficiency.

Final Thoughts on Pore Die Casting and Statistical Optimization

This exploration into pore die casting highlights how material savings and quality control can go hand in hand when process parameters are optimized systematically. The use of statistical methods—particularly through camLine’s Cornerstone software—proved essential in identifying and fine-tuning factors such as piston speed and press residue, which directly impact porosity, surface quality, and component weight.

The findings illustrate that structured data analysis—enabled by Cornerstone’s statistical functions—can bring clarity to complex relationships between casting parameters and product quality. In this case, the implementation of D-optimal experimental design with Cornerstone successfully optimizes the housing of a fuel cell stack.

This approach is also adaptable to other molding processes—such as plastic and battery molding—for manufacturing optimization beyond just pore die casting.

For those interested in a deeper dive into the methodology, results, and broader implications, the full whitepaper is available on the Casting Plant & Technology website.

Citation: Jörg Hohlfeld, Christian Hannemann, Frank Schneider, Christian Fritsch, Andy Günther, Holger Petschel, Theo Wember, René Schmiedel. 2025. "Pore-die-casting – a way to save aluminum?" Casting Plant & Technology, 01/2025, 41–49.