Al'-1 Thermal characteristic curve

Guidelines for mould/AM cooling design

Distance to surface effect Channel surface roughness effect

80 80

u 60
0

tso
.,
70 70
~ 60
ci. 50
E
r AM
Machining

>- 40 ~ 40
30 30
20 20
0 2 4 6 8 10 0 50 100 150 200
Time (sec) Time (sec)
diameter 5 mm diameter 4 mm Distance- 3mm

voestalpine Technology Institute (Asia) Co. Ltd voestalpine

26 I 3/30/2022 I MAGMA Conference_Additive Manufacturing Solution for H PDC Dies_vTI ONE STEPAHE
Thank ou
David Wang
T. +886/49/233 2116
David.Wang@voestalpine.com

voestalpine Technology Institute (Asia) Co. Ltd "• voestalpine

www.voestalpine.com / highperformancemetals/pacif ic
Innovation & customer-value oriented

li)@rij~(fb e~st~mift@lj' Performance

'WL.LUJ~
Property

Manufacturing
Process

Material
Composition

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38 I 3/30/2022 I MAGMA Conference_Additive Manufacturing Solutio n for HPDC Dies_vTI
 Digital

Design Simulation Design for manufacturing

- "~
Meeds/
problems
~A
• Customer benefit SOLUTION

Manufacturing
Physical Physical
■
Production
Physical

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37 I 3/30/2022 I MAGMA Conference_Additive Manufacturing Solutio n for HPDC Dies_vTI ONE STEP AHEAD.
 Design & simulation

Needs/ Design Simulation Performance

problems

voestalpine Technology Institute (Asia) Co. Ltd

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36 I 3/30/2022 I MAGMA Conference_Additive Manufacturing Solution for HPDC Dies_vTI ONE STEP AHEAD.
Benefit of conformal cooling in HPDC

·- 1. Casting quality
-Reduce the roughness on casting surface

i
-Reduce the porosity of the casting
2. Die life
-i -Remove the overheat at critical area
to reduce the soldering index
Conformal Designed Uniformly -Reduce thermal s~ ess
Cooling Water flow Mould Temperature
3. Process time t
-Reduce the spraying & solidification time

voestalpine Technology Institute (Asia) Co. Ltd

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35 I 3/30/2022 I MAGMA Conference_Additive Manufacturing Solutio n for H PDC Dies_vTI ONE STEP AHEAD.
Atv1 insert after ?Ok shots

voestalpine Technology Institute (Asia) Co. Ltd

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34 I 3/30/2022 I MAGMA Conference_Additive Manufacturing Solutio n for H PDC Dies_vTI ONE STEP AHEAD.
Atv1 process of premium solution

1. Hybrid base 2. AM mold part & Heat treatment 3. Machining ♦

5. PVD coating 4. Polishing

voestalpine Technology Institute (Asia) Co. Ltd voestalp1n

33 I 3/30/2022 I MAGMA Conference_Additive Manufacturing Solution for HPDC Dies_vTI
Atv1 solution
Provide Sufficient cooling & Less stress intensity
Cooling channel Temperature on mould Soldering index
M ax. st ress
design surface
» Solution: Conformal cooling design
Original
» Materials: W722 Hybrid
» Process: AM printing
» Machine: EOS M290
» Performance: 666 MPo

1. Reduce mould temperature &

-
Modified
soldering i~ ex
2. Reduce mouid stress: -53%
3. Enhance mould life, from
35k to >?Ok shots I 311 MPo

voestalpine Technology Institute (Asia) Co. Ltd voes a pine

32 I 3/30/2022 I MAGMA Conference_Additive Manufacturing Solutio n for H PDC Dies_vTI ONE STEP AHEAD.
Problems - Soldering & Cracks
» Application: H PDC Hot spot
» Problem: Crack & soldering
» Method: stress analysis & process simulation
» Root cause:
1. Adapted AM solution, still insufficient cooling
2. Stress intensity at cracked area, near cooling
channel
» Approach: redesign cooling channel
» To increase the cooling efficiency
» To reduce the stress state

voestalpine Technology Institute (Asia) Co. Ltd

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31 I 3/30/2022 I MAGMA Conference_Additive Manufacturing Solutio n for HPDC Dies_vTI
Problems - Soldering & Cracks
» Application: H PDC Hot spot
» Problem: Crack & soldering
» Method: stress analysis & process simulation
» Root cause:
1. Adapted AM solution, still insufficient cooling
2. Stress intensity at cracked area, near cooling
channel
» Approach: redesign cooling channel
» To increase the cooling efficiency
» To reduce the stress state

voestalpine Technology Institute (Asia) Co. Ltd

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31 I 3/30/2022 I MAGMA Conference_Additive Manufacturing Solutio n for HPDC Dies_vTI
Reduce spraying time

,r····'11
Temper11ure T~~ture
·c ·c

"""' """'

-H..
207.l 207.l
19].7 19].7

180.4 180.)
167.0 167.0
lSl.6
15].6
140.3 I ,,

,.
126.9 126.9
113.5 113.S

~ I ...
100.2
...'"'".
...,
71.4
...,
73.S

-
46,7

- Ill I
'6.7
I JU
'°'
]1.4
,,.
• ..,.. I 20.0

Modified

Conformal cooling could reduce the spraying time (from12s to 9s)

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30 I 3/30/2022 I MAGMA Conference_Additive Manufacturing Solutio n for HPDC Dies_vTI