Shape-Dependent Strength of Al Si9Cu3FeZn Die-Cast Alloy in Impact Zone of Conformal Cooling Core

Abstract

This article presents the results of shape-dependent strength analyses in die-castings from traditional (straight-drilled) and conformal core-cooling moulds. Cores with a traditional cooling layout were made of H13 steel using machining, and the working sections of the conformal cores were made using the selective laser melting method (SLM). Two series of casts were produced in the same mould. For Series A, the mould was fitted with traditional cooling cores, and for Series B, the same mould was fitted with conformal ones. The cast specimens were subjected to two weeks of natural ageing. The strength testing of the casts determined the levels of the destructive forces. The destructive forces in the core-cooling impact zones were approximately 28% higher in the B samples than they were in the A samples. The impact of the alloy’s porosity, density, and microstructure on the strengths of the casts was demonstrated. The alloy densities in the central (broken-off) fragments of the casts from Series A were 2.6646 g/cm3; these were 2.6791 g/cm3 in the cases of casts from Series B. The values of the secondary dendrite arm space (SDAS) ranged from 6 to 13 μm in the analysed cross-section of the set of the A casts, and between 3 and 12 μm in the same zone of the set of the B casts. The results of the experimental determinations of the casts porosity levels and SDAS parameters were compared with the results of numerical simulations that were carried out in ProCAST software.

Analysis of Phenomenon of Plasticity Loss of Steel Core Made by Selective Laser Melting Method in Zone of Pressure Mould Conformal Cooling Channel

“…The values of the η coefficients for the circumferential notch samples with different radii ρ were calculated based on Equation (5). The radius of ring notch ρ was determined for each sample based on the image that was obtained by the optical microscope; they were measured in the same way.…”

“…The use of the SLM method for fabricating pressure mould parts significantly expands the range of available design solutions for the designed mould cooling system as compared to machining methods. By matching the trajectory of the channels to the shape of the surface of the mould cavity or core, the rate of the heat removal from the solidifying metal is increased, resulting in a more homogeneous temperature field in the casting [ 2 ]; also, shrinkage porosity can be largely eliminated, and a fine-grained structure of the casting can be achieved [ 3 , 4 , 5 ]. This results in a casting with greater mechanical strength and tightness.…”

Method of Stamping the Progression of a Beverage End Rivet of a Thinner Sheet of AW-5182 Alloy

“…Important parameters of aluminium alloys are their ability to be stamped as presented in the publication [ 10 ]. An important area of use of aluminium alloys is the automotive industry, which takes advantage of another feature of aluminium alloys, i.e., their lightness, which significantly reduces the weight of the product [ 11 , 12 , 13 ]. The lightness of the material is also important in the manufacture of aircraft components [ 14 , 15 ].…”

Numerical and Experimental Analysis of Strength Loss of 1.2709 Maraging Steel Produced by Selective Laser Melting (SLM) under Thermo-Mechanical Fatigue Conditions

“…One of the possibilities of using incremental methods using maraging steel powders as a material is to make toolings for injection moulds and die casting moulds; the selective laser melting (SLM) method is most commonly used for this purpose [1]. The reason for applying this unconventional method to the production of mould parts is the possibility of making a cooling system that is optimal in terms of heat transport in a mould [2][3][4][5][6]. The cooling system in a mould part that was made using the SLM method can consist of channel sections with almost any trajectory and cross-sectional shape (as opposed to a traditional system that consists only of rectilinear sections).…”