scholarly journals On the Use of Conformal Cooling in High-Pressure Die-Casting and Semisolid Casting

Technologies ◽  
2021 ◽  
Vol 9 (2) ◽  
pp. 39
Author(s):  
Anders E. W. Jarfors ◽  
Ruslan Sevastopol ◽  
Karamchedu Seshendra ◽  
Qing Zhang ◽  
Jacob Steggo ◽  
...  
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Life Extension ◽  
Conformal Cooling ◽  
High Pressure Die Casting ◽  
Cooling Channels ◽  
Die Life ◽  
Die Materials ◽  
Pressure Die Casting ◽  
Semisolid Casting

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.

scholarly journals Manufacturing of High Pressure Die Casting Die Inserts Using SLM

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.

Reducing Non Value Adding Aluminium Alloy in Production of Parts by High Pressure Die Casting Using High Temperature Die Manufacturing Material

2015 ◽  
Vol 828-829 ◽  
pp. 93-99
Author(s):  
Filipe Pereira ◽  
Martin Williams
Keyword(s):  
High Pressure ◽  
High Temperature ◽  
Die Casting ◽  
Construction Materials ◽  
Tungsten Alloy ◽  
Process Conditions ◽  
Cast Part ◽  
High Pressure Die Casting ◽  
Die Life ◽  
Pressure Die Casting

The difficulties and issues associated with the economics of the process and die life in casting aluminium alloys, as experienced by the high pressure die casting industry, were reasons behind undertaking this research project. The use of a tungsten alloy able to withstand high temperature process conditions without the welding problems experienced by standard die construction materials, such as H13, was examined in an extensive series of casting trials. The importance of operating dies at elevated temperatures to minimize heat checking has been demonstrated previously, both through theoretical thermal modelling and experimentation. This paper describes both aspects of die life extension and possibilities to reduce the amount of alloy material used in the cast part feed system, including overflows. CSIR intends using the results of this research for further development and application of high temperature die construction materials in high pressure die casting processes of light metal alloys.

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

Materials ◽  
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.

Failure analysis of H13 steel die for high pressure die casting Al alloy

2021 ◽  
pp. 105330
Author(s):  
Rengen Ding ◽  
Haibo Yang ◽  
Shuzhi Li ◽  
Guodong Wu ◽  
Jiahao Mo ◽  
...  
Keyword(s):  
High Pressure ◽  
Failure Analysis ◽  
Die Casting ◽  
Al Alloy ◽  
H13 Steel ◽  
High Pressure Die Casting ◽  
Pressure Die Casting

scholarly journals A digital twin approach to predict and compensate distortion in a High Pressure Die Casting (HPDC) process chain

2020 ◽  
Vol 52 ◽  
pp. 144-149
Author(s):  
Alireza Ebrahimi ◽  
Udo Fritsching ◽  
Michael Heuser ◽  
Dirk Lehmhus ◽  
Adrian Struß ◽  
...  
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Process Chain ◽  
High Pressure Die Casting ◽  
Digital Twin ◽  
Pressure Die Casting

Conditions for blister formation during thermal cycles of Al–Si–Cu–Fe alloys for high pressure die-casting

2016 ◽  
Vol 92 ◽  
pp. 151-159 ◽  
Author(s):  
Oksana Ozhoga-Maslovskaja ◽  
Elisabetta Gariboldi ◽  
Jannis Nicolas Lemke
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Thermal Cycles ◽  
Blister Formation ◽  
High Pressure Die Casting ◽  
Fe Alloys ◽  
Pressure Die Casting
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