scholarly journals Analysis of a Special, 3D Metal-Printed HPDC Tool Material

2020 ◽  
Vol 5 (2) ◽  
pp. 251-265
Author(s):  
Sándor Endre Kovács ◽  
László Varga ◽  
Zsolt Szentes
Keyword(s):  
Tool Material ◽  
High Heat ◽  
Metal Casting ◽  
Tool Steels ◽  
Casting Method ◽  
Additive Manufacturing Technology ◽  
Die Cast ◽  
New Perspective ◽  
Pressure Die Casting ◽  
High Heat Conductivity

High Pressure Die Casting (HPDC) is still the most productive metal-casting method of our time, however the more demanding are the industrial expectations, the more challenging it becomes to ensure the creation of the difficult cavity geometries and the thermal balance of the die-cast tool. New perspective is required, thus we can utilize high heat-conductivity tool steels and additive manufacturing technology.

Decision and Design Methodologies for the Lay-Out of Modular Dies for High-Pressure-Die-Cast-Processes

2009 ◽  
Vol 618-619 ◽  
pp. 345-348 ◽  
Author(s):  
Yann Queudeville ◽  
Todor Ivanov ◽  
Christopher Nußbaum ◽  
Uwe Vroomen ◽  
Andreas Bührig-Polaczek
Keyword(s):  
High Pressure ◽  
Design Methodology ◽  
Cost Effective ◽  
Strong Increase ◽  
German Research Foundation ◽  
New Concepts ◽  
Die Cast ◽  
Wide Range ◽  
New Perspective ◽  
Pressure Die Casting

Within the project “Decision and design methodology for the lay-out of modular dies” which is part of the Cluster of Excellence “Integrative Production Technology for High-Wage Countries”, established and financed by the German Research Foundation (DFG), the main objective is setting guidelines for cost-effective and high quality high pressure die casting (HPDC) moulds. The strong increase in product variants and the growing demand for individualised products results in a growing complexity of all related products. The main objective of this project is bridging the existing gap between individual manufacturing and mass production. A new perspective on the value creation chain of HPDC-dies has to be established. First of all, the methodology for the lay-out of modular dies consists in an analysis of the already produced die cast moulds. For the development of modules, standard parts, and different die types, a wide range of HPDC-dies will be compared with each other and subsequently clustered along specific criteria such as size or number of core sliders. Another step consists in optimising setting-up time and maintenance. The as-is state in different companies will be examined. With this knowledge, new concepts will be developed, keeping a modular configuration of the different parts involved in mind. Concepts for modular core sliders, guides and ejectors will be developed and will be investigated for further use. Based on this information, the decision and design methodology for the lay-out of modular HPDC -dies will be examined and developed throughout the process.

Application Experiences in Powder Compaction of Iron Powder - Influence of Tool Material on Tool Life

2007 ◽  
Vol 534-536 ◽  
pp. 649-652
Author(s):  
Odd Sandberg ◽  
Andreas Krona ◽  
Sigurd Berg ◽  
Flemming Kaad ◽  
Göran Nord
Keyword(s):  
Tool Life ◽  
Tool Steel ◽  
Compaction Pressure ◽  
Tool Material ◽  
High Hardness ◽  
Full Potential ◽  
Tool Steels ◽  
Low Friction ◽  
Powder Pressing ◽  
Type Size

Tool steels for powder pressing are normally heat treated to a high hardness to counteract plastic deformation during the compacting process. Ductility and wear resistance of the die punch or core rod are determined by the type, size, amount, hardness and distribution of the hard phase in the martensitic matrix. Thus, tool steels can be designed and optimized for specific powder pressing application. To be able to utilize the full potential of the tool steel, also the design, heat treatment and eventual surface coating of the steel must be taken into account. In this paper new low-friction tool steel is investigated in PM manufacturing for a number of applications. An increase of tool life of more than two times compared to ordinary tool steels is found. Furthermore, the new low friction tool steel shows a potential for sintered parts with higher densities through the applicability of increased compaction pressure or minimized lubricant amount.

scholarly journals Numerical analysis of plastic die deformation during high temperature copper extrusion

2021 ◽  
Author(s):  
Stefan Lechner ◽  
Renè Nitschke ◽  
Sören Müller
Keyword(s):  
Plastic Deformation ◽  
High Temperature ◽  
Mechanical Load ◽  
Residual Deformation ◽  
Tool Material ◽  
Load Cycle ◽  
Compression Tests ◽  
Tool Steels ◽  
Die Deflection ◽  
Hot Work Tool Steels

In copper extrusion, billet temperatures of 600°C or more are very common and the dies are therefore exposed to high thermo-mechanical stress. This causes deflection and wear of the dies and thus reduced quality of the extruded profile. In the present study, die deflection and residual deformation after several extrusion cycles was investigated by means of extrusion trials and numerical analyses. Material models of four tool materials (hot-work tool steels 1.2367 and CS1, nickel-based alloy 718, cobalt-based alloy Stellite 1) and the copper alloy CW024A were provided by hot compression tests. Extrusion trials were carried out applying four different dies, each made of another tool material. Using the FEM based software DEFORM 2D, the extrusion trials were modeled and decoupled die stress analyses were performed, which simulated three consecutive load cycles. The focus of the data interpretation was in die deflection in proximity of the die land due to the thermo-mechanical load and residual plastic deformation after relief of the mechanical load. Larger values of deflection close to the die land were observed for the hot-work tool steels, while the deflection of nickel- and cobalt-based alloys was negligibly small. Also, remarkable plastic deformation was only determined for the hot-work tool steels, with increasing values for every simulated load cycle. This analysis characterizes the performance limits of hot-work tool steels and the benefits of nickel- and cobalt-based alloys regarding contour accuracy during high temperature copper extrusion.

scholarly journals Evaluation of NaCl and MgCl2 heat exchange fluids in a deep binary geothermal system in a sedimentary halite formation

2020 ◽  
Author(s):  
Kayla R Moore ◽  
Hartmut M. Holländer
Keyword(s):  
Heat Exchange ◽  
Reactive Transport ◽  
High Heat ◽  
Saturated Formation ◽  
Geothermal System ◽  
Production Well ◽  
Well Clogging ◽  
Geochemical Reactions ◽  
Inform Decision Making ◽  
High Heat Conductivity

Abstract Halite formations are attractive geothermal reservoirs due to their high heat conductivity, resulting in higher temperatures than other formations at similar depths. However, halite formations are highly reactive with undersaturated water. An understanding of the geochemical reactions that occur within halite-saturated formation waters can inform decision making regarding well construction, prevention of well clogging, formation dissolution, and thermal short-circuiting. Batch reaction and numerical 3-D flow and equilibrium reactive transport modeling were used to characterize the produced NaCl-brine in a well targeting a halite-saturated formation. The potential for inhibition of precipitation and dissolution using an MgCl2-brine and NaCl+MgCl2-brine were also investigated. Within the injection well for an NaCl-brine, with heating from 70 to 120°C, the solubility of halite decreases resulting in the potential dissolution of 0.479 mol kg-1 halite at the formation. Cooling from 120 to 100°C in the production well results in precipitation of 0.196 mol kg-1 halite as well as anhydrite. Introduction of MgCl2, resulting in a common Cl- ion, into the heat exchange brine resulted in a decreased potential for dissolution by 0.290 mol kg-1 halite within the formation, as well as decreased precipitation within the production well, compared to the NaCl-brine. The halite solubility was altered by changes in pressure up to 0.045 mol kg-1. This indicates that designing and monitoring the composition of heat exchange fluids in highly saline environments is an important component in geothermal project design.

New Technique of Developing a Composite by the Penetration of Hard Powders Into Metal Pipe

2006 ◽  
Author(s):  
Shigeru Tanaka ◽  
Kazuyuki Hokamoto ◽  
Shigeru Itoh
Keyword(s):  
Shock Wave ◽  
Composite Material ◽  
Heat Conductivity ◽  
High Heat ◽  
Experimental Conditions ◽  
Metal Pipe ◽  
Conductivity Property ◽  
The Difference ◽  
Diamond Powders ◽  
High Heat Conductivity

A new attempt in developing a composite material using explosive processing was attempted. Shock wave derived from explosion energy is a viable technique and can be used to penetrate diamond powders into the metal pipe without permitting the reaction with the base metal. In this method, the overall heat conductivity property of the composite is expected to be improved by the diamond powders, which possess high heat conductivity property. The purpose of this research is to clarify the experimental conditions for obtaining a new composite material with unique properties. Some sizes powders were used for the experiments and the difference in the experimental results are reported.

Simulation of Inner Rim Compression Test of Aluminum Alloy Wheels

2018 ◽  
Vol 774 ◽  
pp. 379-384
Author(s):  
Ali Kara ◽  
Orbay Daysal
Keyword(s):  
Aluminum Alloy ◽  
Compression Test ◽  
A356 Alloy ◽  
Mechanical Tests ◽  
Failure Behavior ◽  
Casting Method ◽  
Passenger Cars ◽  
Finite Element Software ◽  
Visual Impact ◽  
Pressure Die Casting

Aluminum alloy wheels are the most commonly used wheel type for passenger cars for decades. Generally A356 alloy (including alloying elements of 7% Si and 0.3% Mg) is used and a T6 heat treatment (solutionizing and artificial aging) is applied for the wheels. The most commonly used casting method is the Low Pressure Die Casting method for the wheels. As a cast product, wheels are one of the most important safety parts of a car along with a huge visual impact on the car. Therefore a lot of proofing tests are applied on a wheel in order to ensure its reliability and to guarantee passenger safety. Inner rim compression test of aluminum alloy wheels is one of these important mechanical tests which is a quasi-static deformation test to determine the fracture and failure behavior of the wheel. In this test, wheel is fixed at its offset surface using lug nuts and a crosshead applies the load with an offset from the inner rim position applying the biggest stress to the valve hole section. This study comprises the efforts of simulation of this test. In the study, ABAQUS finite element software is used and results were compared with experimentally obtained results.

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