Cast Component Development for High Cycle Fatigue in the Precision Sand Casting Process (PSCP)

The precision sand casting process (PSCP) is used to manufacture components that typically have complex architectures but also must sustain high cyclical compression and tensile loads in service conditions. Literature generally argues the key to improve tensile and fatigue performance in PSCP is to keep porosity as low as possible. This article outlines the key elements in the current PSCP evolution which have addressed improved high cycle fatigue performance and identifies the areas of research needed in the future to further push secondary aluminum in fatigue performance.