Effect of conformal cooling in Additive Manufactured inserts on properties of high pressure die cast aluminum component

Additive manufacturing can bring several advantages in tooling applications especially hot working tooling as high pressure die casting. Printing of conformal cooling channels can lead to improved cooling and faster solidification, which, in turn, can possibly result in better quality of the cast pa...

Full description

Bibliographic Details
Main Author: Sevastopolev, Ruslan
Format: Others
Language:English
Published: Jönköping University 2020
Subjects:
Online Access:http://urn.kb.se/resolve?urn=urn:nbn:se:hj:diva-50949
id ndltd-UPSALLA1-oai-DiVA.org-hj-50949
record_format oai_dc
spelling ndltd-UPSALLA1-oai-DiVA.org-hj-509492021-05-28T05:52:58ZEffect of conformal cooling in Additive Manufactured inserts on properties of high pressure die cast aluminum componentengSevastopolev, RuslanJönköping University10032020High Pressure Die Casting (HPDC)Additive Manufacturing (AM)Aluminum (Al)Tensile testCooling channelsConformal coolingLaser Based Power Bed Fusion of Metals (PBF-LB/M)MicrostructureSecondary Dendrite Arm Spacing (SDAS).Metallurgy and Metallic MaterialsMetallurgi och metalliska materialAdditive manufacturing can bring several advantages in tooling applications especially hot working tooling as high pressure die casting. Printing of conformal cooling channels can lead to improved cooling and faster solidification, which, in turn, can possibly result in better quality of the cast part. However, few studies on advantages of additive manufactured tools in high pressure die casting are published.The aim of this study was to investigate and quantify the effect of conformal cooling on microstructure and mechanical properties of high pressure die cast aluminum alloy. Two tools each consisting of two die inserts were produced with and without conformal channels using additive manufacturing. Both tools were used in die casting of aluminum alloy. Aluminum specimens were then characterized microstructurally in light optical microscope for secondary arm spacing measurements and subjected to tensile and hardness testing. Cooling behavior of different inserts was studied with a thermal camera and by monitoring the temperature change of cooling oil during casting. Surface roughness of die inserts was measured with profilometer before and after casting.Thermal imaging of temperature as a function of time and temperature change of oil during casting cycle indicated that conformal insert had faster cooling and lower temperature compared to conventional insert. However, thermal imaging of temperature after each shot in a certain point of time showed higher maximum and minimum temperature on conformal die surface but no significant difference in normalized temperature gradient compared to the conventional insert.The average secondary dendrite arm spacing values were fairly similar for samples from conventional and conformal inserts, while more specimens from conventional insert demonstrated coarser structure. Slower cooling in conventional insert could result in the coarser secondary dendrite arm spacing.Tensile strength and hardness testing revealed no significant difference in mechanical properties of the specimens cast in conventional and conformal die inserts. However, reduced deviations in hardness was observed for samples cast with conformal insert. This is in agreement with secondary dendrite arm spacing measurements indicating improved cooling with conformal insert.Surface roughness measurement showed small wear of the inserts. More castings are needed to observe a possible difference in wear between the conventional and conformal inserts.Small observed differences in cooling rate and secondary arm spacing did not result in evident difference in mechanical properties of the aluminum alloy but the variation in properties were reduced for samples cast with conformal cooling. Future work may include more accurate measurement of cooling behavior with a thermocouple printed into the die insert, casting of thicker specimen for porosity evaluation and fatigue testing and longer casting series to evaluate the influence of conformal cooling on tool wear. Student thesisinfo:eu-repo/semantics/bachelorThesistexthttp://urn.kb.se/resolve?urn=urn:nbn:se:hj:diva-50949application/pdfinfo:eu-repo/semantics/openAccess
collection NDLTD
language English
format Others
sources NDLTD
topic High Pressure Die Casting (HPDC)
Additive Manufacturing (AM)
Aluminum (Al)
Tensile test
Cooling channels
Conformal cooling
Laser Based Power Bed Fusion of Metals (PBF-LB/M)
Microstructure
Secondary Dendrite Arm Spacing (SDAS).
Metallurgy and Metallic Materials
Metallurgi och metalliska material
spellingShingle High Pressure Die Casting (HPDC)
Additive Manufacturing (AM)
Aluminum (Al)
Tensile test
Cooling channels
Conformal cooling
Laser Based Power Bed Fusion of Metals (PBF-LB/M)
Microstructure
Secondary Dendrite Arm Spacing (SDAS).
Metallurgy and Metallic Materials
Metallurgi och metalliska material
Sevastopolev, Ruslan
Effect of conformal cooling in Additive Manufactured inserts on properties of high pressure die cast aluminum component
description Additive manufacturing can bring several advantages in tooling applications especially hot working tooling as high pressure die casting. Printing of conformal cooling channels can lead to improved cooling and faster solidification, which, in turn, can possibly result in better quality of the cast part. However, few studies on advantages of additive manufactured tools in high pressure die casting are published.The aim of this study was to investigate and quantify the effect of conformal cooling on microstructure and mechanical properties of high pressure die cast aluminum alloy. Two tools each consisting of two die inserts were produced with and without conformal channels using additive manufacturing. Both tools were used in die casting of aluminum alloy. Aluminum specimens were then characterized microstructurally in light optical microscope for secondary arm spacing measurements and subjected to tensile and hardness testing. Cooling behavior of different inserts was studied with a thermal camera and by monitoring the temperature change of cooling oil during casting. Surface roughness of die inserts was measured with profilometer before and after casting.Thermal imaging of temperature as a function of time and temperature change of oil during casting cycle indicated that conformal insert had faster cooling and lower temperature compared to conventional insert. However, thermal imaging of temperature after each shot in a certain point of time showed higher maximum and minimum temperature on conformal die surface but no significant difference in normalized temperature gradient compared to the conventional insert.The average secondary dendrite arm spacing values were fairly similar for samples from conventional and conformal inserts, while more specimens from conventional insert demonstrated coarser structure. Slower cooling in conventional insert could result in the coarser secondary dendrite arm spacing.Tensile strength and hardness testing revealed no significant difference in mechanical properties of the specimens cast in conventional and conformal die inserts. However, reduced deviations in hardness was observed for samples cast with conformal insert. This is in agreement with secondary dendrite arm spacing measurements indicating improved cooling with conformal insert.Surface roughness measurement showed small wear of the inserts. More castings are needed to observe a possible difference in wear between the conventional and conformal inserts.Small observed differences in cooling rate and secondary arm spacing did not result in evident difference in mechanical properties of the aluminum alloy but the variation in properties were reduced for samples cast with conformal cooling. Future work may include more accurate measurement of cooling behavior with a thermocouple printed into the die insert, casting of thicker specimen for porosity evaluation and fatigue testing and longer casting series to evaluate the influence of conformal cooling on tool wear.
author Sevastopolev, Ruslan
author_facet Sevastopolev, Ruslan
author_sort Sevastopolev, Ruslan
title Effect of conformal cooling in Additive Manufactured inserts on properties of high pressure die cast aluminum component
title_short Effect of conformal cooling in Additive Manufactured inserts on properties of high pressure die cast aluminum component
title_full Effect of conformal cooling in Additive Manufactured inserts on properties of high pressure die cast aluminum component
title_fullStr Effect of conformal cooling in Additive Manufactured inserts on properties of high pressure die cast aluminum component
title_full_unstemmed Effect of conformal cooling in Additive Manufactured inserts on properties of high pressure die cast aluminum component
title_sort effect of conformal cooling in additive manufactured inserts on properties of high pressure die cast aluminum component
publisher Jönköping University
publishDate 2020
url http://urn.kb.se/resolve?urn=urn:nbn:se:hj:diva-50949
work_keys_str_mv AT sevastopolevruslan effectofconformalcoolinginadditivemanufacturedinsertsonpropertiesofhighpressurediecastaluminumcomponent
_version_ 1719408042230939648