Abstract:

Authors: Sevda Fathipour, Abdallah Elsayed

Keywords: additive manufacturing, aluminum, die soldering, heat checking, high pressure die casting, tool steel

During high pressure die casting of aluminum, the tool steel die is exposed to many alternating heating and cooling cycles, causing tension-compression states leading to cyclic deformation. This deformation results in cracking of the tool steel called heat checking. For next generation high pressure die cast aluminum alloys, the complex geometries needed are only accomplished by utilizing additive tool steel inserts. The failure of additive tooling is costly and replacements require expensive insert changeovers. The objective of this research is to investigate the failure of additive tool steel inserts for high pressure die cast aluminum.

Sample additive tool steel inserts were produced and immersed in a cyclic fashion into molten aluminum to simulate heat checking and die soldering during high pressure die casting. The microstructure of the additive inserts and their failure was characterized using optical and electron microscopy. Future research aims to develop a new additive strategy to optimize the inserts for high pressure die casting to reduce heat checking and die soldering. Additive tool steel inserts are necessary for the next generation of aluminum alloy castings crucial for sustainable transportation.

Keywords: additive manufacturing, aluminum, die soldering, heat checking, high pressure die casting, tool steel

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Mrs. Sevda Fathipour