Enhanced cooling channel efficiency of high-pressure die-casting molds with pure copper linings in cooling channels via explosive bonding

Today, tool life in high pressure die casting (HPDC) is of growing interest. A common agreement is that die life is primarily decided by the thermal load and temperature gradients in the die materials. Conformal cooling with the growth of additive manufacturing has raised interest as a means of extending die life. In the current paper, conformal cooling channels’ performance and effect on the thermal cycle in high-pressure die casting and rheocasting are investigated for conventional HPDC and semisolid processing. It was found that conformal cooling aids die temperature reduction, and the use of die spray may be reduced and support the die-life extension. For the die filling, the increased temperature was possibly counterproductive. Instead, it was found that the main focus for conformal cooling should be focused to manage temperature around the in-let bushing and possibly the runner system. Due to the possible higher inlet pressures for semisolid casting, particular benefits could be seen.

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Manufacturing of High Pressure Die Casting Die Inserts Using SLM

Advances in Transdisciplinary Engineering - SPS2020 ◽

10.3233/atde200206 ◽

2020 ◽

Author(s):

Roland Stolt ◽

Anders E.W. Jarfors

Keyword(s):

High Pressure ◽

Die Casting ◽

Steel Powder ◽

Rough Machining ◽

High Pressure Die Casting ◽

Manufacturing Method ◽

Cooling Channels ◽

Die Casting Die ◽

Current Design ◽

Pressure Die Casting

Dies for high pressure die casting are normally manufactured by machining of slabs of tool steel to the required dimensions. This manufacturing requires several steps such as rough machining, heat-treatment, EDM (electro discharge machining) and polishing. With the AM (additive manufacturing) method SLM (Selective Laser Melting) it has become possible to print the dies fully or in part. Several advantages are expected, such as a better thermal distribution in the die in service and thereby extended die life and better component quality. This is due to the possibility of making the cooling channels conformal. There are also expectations of reduced time and cost in the manufacturing process due to fewer manufacturing steps and better material utilisation. Hopes are to print a net shape or near net shape that can be used directly as a die component. In this paper it is investigated to what extent this can be fulfilled by printing two die inserts to be used for casting fatigue test samples of aluminium. They were printed on a 3D Systems ProX DMP 300 in maraging steel powder. The result is that it is possible to obtain a sufficiently smooth surface die surface. However, the current design with an SLM insert fitted in a machined die makes extensive post printing manufacturing necessary.

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Die design and optimization of cooling channel position for cold chamber high pressure die casting machine

IOP Conference Series Materials Science and Engineering ◽

10.1088/1757-899x/810/1/012017 ◽

2020 ◽

Vol 810 ◽

pp. 012017

Author(s):

Radhika Chavan ◽

P S Kulkarni

Keyword(s):

High Pressure ◽

Die Casting ◽

Casting Machine ◽

Die Design ◽

Cooling Channel ◽

High Pressure Die Casting ◽

Design And Optimization ◽

Cold Chamber ◽

Pressure Die Casting

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A Development of Virtual Manufacturing System for Magnesium High Pressure Die Casting Processes

Materials ◽

10.1115/imece2003-55228 ◽

2003 ◽

Author(s):

Weilong Chen

Keyword(s):

High Pressure ◽

Magnesium Alloys ◽

Die Casting ◽

Virtual Manufacturing ◽

Mold Design ◽

High Pressure Die Casting ◽

Molten Magnesium ◽

Pressure Die Casting ◽

Soft And Hardware ◽

Free Magnesium

In recent years, high-pressure die-casting magnesium components have been gaining currency worldwide because of the excellent properties that magnesium alloys can offer to meet new product requirements. With the increasing application of magnesium parts worldwide, many research and development projects have been carried out to advance HPDC technology. However, truly optimized mold design and production of defect free castings remains a challenge for die casters. For many HPDC magnesium products, especially those specified for porosity-free and high cosmetic requirement, the challenge not only comes form a lack of a deeper understanding of how molten magnesium alloys fill the mold cavity and form defects, but also from improper preliminary part design. This study proposes a virtual prototyping system that integrates several effective soft and hardware tools for both the part and mold-design engineer to evaluate part manufacturability. Also, investigated in this study are the major causes of those defects that are the predominant cause of rejection of thin walled, leak-free magnesium parts requiring highly cosmetic finishes.

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