Advancing Strategies for Distortion Control in Megacasting: Critical Parameters and Compensation Techniques

Abstract Megacasting, also known as gigacasting, is an emerging high-pressure die casting (HPDC) technology that enables the production of large, complex aluminum components in a single piece. This disruptive approach offers potential benefits in terms of reduced part count, lower assembly cost, and improved structural performance. However, the process also introduces significant challenges in maintaining tight geometrical tolerances due to distortion caused by residual stresses and non-uniform cooling. This study advances strategies for minimizing distortion by combining insights from interviews, physical tests, and literature. Key process parameters, including tool compensation, quenching, and fixturing, are identified and analyzed. A balanced approach is proposed, integrating predictive tool compensation and fixturing during quenching to reduce distortion. The findings present a novel framework for controlling distortion while meeting both material and geometrical quality requirements in megacast components, paving the way for more sustainable and competitive manufacturing practices in the automotive industry.This paper represents one of the first structured efforts to integrate empirical shop-floor experience, existing literature, and early-stage testing to address distortion control in megacasting.