High-pressure die casting (HPDC) is commonly used to produce large volumes of nonferrous components efficiently and inexpensively with complex and near-net shapes for a broad range of industries. The predominant failure mode of HPDC tooling and dies is thermal fatigue, leading to heat-checking or cracking. The thermal design and management in the die play a major role as it can be used to redistribute the stresses and reduce thermal gradients and thus improve the performance of the die and lifetime. Laser powder bed fusion (LPBF) is a 3D-printing technique that produces a component via a layer-by-layer process. Due to its nature, this technique allows the implementation of conformal cooling channels into tooling inserts, that is channels that are designed to be equidistant from the die surface thus helping in managing the thermal gradients and stresses that arise during the HPDC process. This work is a brief overview of how LPBF technology enables the die-casting industry to better control the thermal aspects of the die and ultimately produce better castings.

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The Use of Laser Powder Bed Fusion in the Manufacturing of Tooling for High-Pressure Die-Casting Applications

  • Khaled Abu Samk,
  • Jack Olsen,
  • Wessel Byleveld

摘要

High-pressure die casting (HPDC) is commonly used to produce large volumes of nonferrous components efficiently and inexpensively with complex and near-net shapes for a broad range of industries. The predominant failure mode of HPDC tooling and dies is thermal fatigue, leading to heat-checking or cracking. The thermal design and management in the die play a major role as it can be used to redistribute the stresses and reduce thermal gradients and thus improve the performance of the die and lifetime. Laser powder bed fusion (LPBF) is a 3D-printing technique that produces a component via a layer-by-layer process. Due to its nature, this technique allows the implementation of conformal cooling channels into tooling inserts, that is channels that are designed to be equidistant from the die surface thus helping in managing the thermal gradients and stresses that arise during the HPDC process. This work is a brief overview of how LPBF technology enables the die-casting industry to better control the thermal aspects of the die and ultimately produce better castings.