The aim of this work is to give an overview of existing methods and to introduce three new methods for the determination of the Dendrite Coherency Point (DCP) for AlSi₁₀Mg alloys, as well as to compare the acquired values of DCP based on a thermal analysis and on the analysis of cooling curves working with only one thermocouple. Additionally, the impact of alloying and contaminant elements on the DCP will be also studied. The first two proposed methods employ the higher order derivatives of the cooling curves. The DCP was determined as the crossing point of the second and third derivative curves plotted versus time (method 1) or that of the temperature (method 2) with the zero line just after the maximum liquidus temperature. The third proposed method is based on the determination of the crossing point of the third solid fraction derivative curve with the zero line, corresponding to a minimum of the second derivative. A Taguchi design for the experiments was developed to study the DCP values in the AlSi₁₀Mg alloy. The DCP temperature values of the test alloys were compared with the DCP temperatures predicted by the previous methods and the influence of the major and minor alloying elements and contaminants over the DCP. The new processes obtained a correlation factor r² from 0.954 and 0.979 and a standard deviation from 1.84 to 2.6 °C. The obtained correlation values are higher or similar than those obtained using previous methods with an easier way to define the DCP, allowing for a better automation of the accuracy of DCP determination. The use of derivative curves plotted versus temperature employed in the last two proposed methods, where the test samples did not have an influence over the registration curves, is proposed to have a better accuracy than those of the previously described methods.

One of the most important factors in the LPDC process is the heat transfer during the solidification of the molten alloys, which is responsible for the resulting microstructure and, thus, the quality of the cast piece. The use of foundry coatings has been lately suggested as a proper strategy to control the heat transfer while protecting bonded moulds from aluminium adhesion by providing a barrier between the surface and the liquid metal. LPDC die coating failures usually come from the loss of adherence or excessive wear originated in the successive filling processes, which requires stopping production for the reapplication of the coating. In the present work, coatings with different insulation capabilities have been evaluated, in terms of adherence and wear tests, in order to select the most promising alternative for LPDC die coating. This study confirmed that surface preparation and cleanliness are vital for an adequate adhesion of the coatings to ensure their durability. The results evinced that the use of a primer layer provided a higher adhesion of the coatings and considerably improved their perfomance. The coating that presented the best results in terms of adhesion and wear resistance under different abrasive testing conditions was coating B3.

The aim of this work is to determine the Solid Fraction (SF) at the rigidity point (FRP) by applying advanced thermal analysis techniques. The variation of the FRP value is important to explain the solidification behavior and the presence or absence of defects in aluminum alloys. As the final alloy composition plays a key role on obtained properties, the influence of major and minor alloying elements on FRP has been studied. A Taguchi design of experiments and a previously developed calculating method, based on the application of high rank derivatives has been employed to determinate first the rigidity point temperature (RPT) and after the corresponding FRP for AlSi₁₀Mg alloys. A correlation factor of r² of 0.81 was obtained for FRP calculation formula in function of the alloy composition.

The quantitative assessment of industrial decarbonization technologies is essential to objectively compare different processes and to facilitate the transfer of successful decarbonisation solutions across Hard-to-Abate Industries (HTAIs). However, existing Key Performance Indicator (KPI) frameworks differ considerably in KPI selection and definition, calculation methodologies, reporting units, and system boundaries, limiting direct comparison between different technologies and industrial sectors. This work proposes a harmonised KPI framework for the assessment of hydrogen combustion technologies in HTAIs. The framework integrates and harmonises relevant existing indicators while introducing specific KPI formulations and developments tailored to hydrogen combustion assessment. Its development was based on information from the scientific literature, European strategic initiatives, industrial reference documents, and the requirements of the H2AL and HYINHEAT EU projects. A total of 29 KPIs were identified, harmonised, and organised into six assessment categories: energy efficiency, material efficiency, atmospheric emissions, waste and by-product generation, product quality, and competitiveness. The applicability of the framework was initially assessed using industrial data from an aluminium high-pressure die-casting (HPDC) process employing natural gas–air combustion. The results demonstrated the applicability of the proposed framework under real industrial conditions and established an industrial baseline for future comparison with hydrogen combustion technologies. The proposed framework provides a practical and harmonised methodology for the assessment and future comparison of hydrogen combustion technologies across HTAIs.