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

Anders E W Jarfors,Ruslan Sevastopol,Roland Stolt,Qing Zhang,Karamchedu Seshendra,Jacob Steggo

doi:10.3390/technologies9020039

Anders E W Jarfors, Ruslan Sevastopol + Show 4 more

Open Access

https://doi.org/10.3390/technologies9020039

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Journal: Technologies	Publication Date: May 21, 2021
Citations: 5	License type: CC BY 4.0

Affiliation: Jönköping University

Abstract

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.

Highlights

There is a strong focus on tool life in high pressure die casting (HPDC).Die life is primarily decided by the thermal load and temperature gradients in the die materials
The reason for both casting in a conventional molten mode and a semisolid mode is that the heat transfer coefficient for semisolid casting is significantly lower than for conventional casting, possibly influencing the temperature distribution in the die material [7]
The casting was made in two different modes with and without conformal cooling and semisolid and conventional fully molten high pressure die casting mode

Summary

Introduction

Die life is primarily decided by the thermal load and temperature gradients in the die materials. Sivertsen [1] concluded that die life prediction based on thermal stress could be used to predict the failure’s location and that the gate area was common for a part cast using AlMg5Si2Mn. The stresses arise as a consequence of thermal load. Sivertsen [1] concluded that mould erosion was very predictable and directly related to the die design and could be minimized using process parameters targeting a low local fill speed. The most crucial process parameter to achieve longer die life was the tempering channels based on the assumption that effective heat removal promotes long die life

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