The pressure is increased at the end of the die cavity filling, and it is referred to as the intensification (pressure). Many have attempted to solve the problem: what is the required pressure. Yet, there is no a single article that has a successful (even reasonable) answer or model so the process can be understood and a determination what is the minimum ideal pressure. The strange idea that the numerical simulations without getting the physics involve can produce any advance is very common in the field. The numerical works have never produce any substantive solution without a real physics input, in other words: no solution was produced. Thus, experimental techniques were employed. So, it is a typical practice in die casting to use statistical analysis or a case study where arbitrary values experimentally are employed. Every time the term statistical study is used, it is a code name to mean that “we have no clue on what is going on”. The study of minimum ideal required intensification pressure has only case of experimental study or random value of pressure is used. Generally, it has been assumed that the intensification should be done to compensate for the shrinkage porosity and/or entrapment porosity without knowing the actual value to which the intensification should be increased. In fact, there are numerous poorly done research attempts to experimentally study the relationship between the intensification pressure and the properties of the cast material. Of course these attempts did not provide any meaningful idea. The current study is done from a physical point of view based on physical reasoning plus with analytical approach. This analysis provides a solution (or maybe even the solution) for the minimum ideal pressure. For the first time, the relation between the casted material and the operational requirement is provided.

This is breakthrough work on the pressure intensification in die casting.