A KPI-Based Model for Improving Aluminium Alloy Casting Processes: Effects on Material Properties of Castings

In the context of increasing requirements for product quality and reduction in environmental impact, the improvement of aluminium alloy casting processes has become an important research area within Industry 4.0 and industrial digitalisation. The aim of this study was to develop a KPI-based model supporting the optimisation of high-pressure aluminium alloy casting processes, considering its influence on material properties and environmental performance. An important aspect of the proposed model is its adaptive potential and its implementation in real industrial conditions, which increases its application relevance in modern production systems. A set of key performance indicators describing process stability, quality, and resource efficiency was defined and linked to casting process parameters. KPI dashboards were developed to support the visualisation and analysis of key process parameters in relation to main and auxiliary processes. The analysis included microstructure evaluation and mechanical property assessment as a function of KPI values. The results confirm that the integration of KPIs within an Industry 4.0-oriented approach under conditions of industrial digitalisation supports effective optimisation of high-pressure aluminium alloy casting processes, leading to improved material quality and improved production sustainability.