Investigation of effect of conformal cooling inserts in high-pressure die casting of AlSi9Cu3

Karakoc, Can; Dizdar, Kerem Can; Dışpınar, Derya

doi:10.1007/s00170-022-09808-7

Cited by 9 publications

(5 citation statements)

References 36 publications

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“…and increases the efficiency of the HPDC process. Compared to drilled cooling channels, up to 30% reduction in cooling time is achieved with AM moulds with conformal channels [6,7]. GD Druckguss is a manufacturer of zinc alloy castings.…”

Section: Methodsmentioning

confidence: 99%

An Introduction to the Methodology of Quality Monitoring of Zinc Alloy Castings Produced by HPDC in Additively Manufactured Shaped Mould Parts

Koza,

Gryc,

Socha

et al. 2024

Mm 2023

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Section: Methodsmentioning

confidence: 99%

An Introduction to the Methodology of Quality Monitoring of Zinc Alloy Castings Produced by HPDC in Additively Manufactured Shaped Mould Parts

Koza,

Gryc,

Socha

et al. 2024

Mm 2023

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“…In the HPDC process, it is commonly verified that scrap rates of 5 to 10% due to the occurrence up to 30 specific types of defects can occur. Some of the most common defects that have a direct effect on mechanical properties are gas porosity and oxide films, similar to LPC [6,8,29]. Other defects can occur when further processes are applied to HPDC parts, specifically heat treatment.…”

Section: Defectsmentioning

confidence: 99%

Low- and High-Pressure Casting Aluminum Alloys: A Review

Nunes¹,

Emadinia²,

Vieira³

et al. 2024

Recent Advancements in Aluminum Alloys

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Low- pressure casting and high-pressure casting processes are the most common liquid-based technologies used to produce aluminum components. Processing conditions such as cooling rate and pressure level greatly influence the microstructure, mechanical properties, and heat treatment response of the Al alloys produced through these casting techniques. The performance of heat treatment depends on the alloy’s chemical composition and the casting condition such as the vacuum required for high-pressure casting, thus, highlighting the low-pressure casting application that does not require a vacuum. The level of pressure applied to fill the mold cavity can affect the formation of gas porosities and oxide films in the cast. Moreover, mechanical properties are influenced by the microstructure, i.e., secondary dendritic arm spacing, grain size, and the morphology of the secondary phases in the α-matrix. Thus, the current study evaluates the most current research developments performed to reduce these defects and to improve the mechanical performance of the casts produced by low- and high-pressure casting.

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“…Minimizing temperature variations throughout the casting is essential to enhance the overall mechanical characteristics, as well as for reducing the likelihood of porosity formation [8]. A recent investigation into the effect of conformal cooling inserts in the high-pressure die casting of AlSi9Cu3 demonstrated a 43% decrease in porosity when conformal cooling channels were designed in a die casting mold using the additive manufacturing technique known as Direct Metal Laser Sintering (DMLS) [9].…”

Section: Introductionmentioning

confidence: 99%

Thermo-Mechanical Optimization of Die Casting Molds Using Topology Optimization and Numerical Simulations

Djabraian,

Teichmann,

Müller

2024

Materials

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Conventional cooling channels used in die casting molds exhibit significant drawbacks, resulting in extended cooling times for cast parts. Issues such as the formation of dirt, limescale, and corrosion substantially diminish the thermal efficiency of these channels, leading to challenges in achieving uniform cooling and potential quality issues. In response to these challenges, this study proposes Topology Optimization as a novel approach. It involves designing cooling structures through Topology Optimization to replace traditional cooling channels, incorporating both Discrete and Gaussian boundary conditions to optimize thermal efficiency. Additionally, Structural Topology Optimization is employed to ensure structural integrity, preventing deformation or yielding under high loads during the die casting process. Numerical analysis revealed superior thermal performance compared to conventional channels, particularly when subjected to Discrete and Gaussian boundary conditions. Furthermore, the application of the latter establishes conformal cooling and minimizes temperature gradients in the casting, reducing casting defects such as shrinkage porosity. These findings highlight the efficacy of Topology Optimization in addressing the challenges of traditional cooling methods, with wide-ranging implications for manufacturing processes utilizing permanent molds for shaping materials.

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Investigation of effect of conformal cooling inserts in high-pressure die casting of AlSi9Cu3

Cited by 9 publications

References 36 publications

An Introduction to the Methodology of Quality Monitoring of Zinc Alloy Castings Produced by HPDC in Additively Manufactured Shaped Mould Parts

An Introduction to the Methodology of Quality Monitoring of Zinc Alloy Castings Produced by HPDC in Additively Manufactured Shaped Mould Parts

Low- and High-Pressure Casting Aluminum Alloys: A Review

Thermo-Mechanical Optimization of Die Casting Molds Using Topology Optimization and Numerical Simulations

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