Abstract: Proper thermal management during the high pressure die casting (HPDC) process is essential for generating high-quality cast components as well as preserving mold life. Metal additive manufacturing offers unique benefits in the rapid production of casting dies and tooling. Novel technologies enabled through additive manufacturing, such as conformal cooling and heating lines, allow for truncated cycle times and more uniform heat extraction as compared to conventionally drilled channels. However, premature failure of the mold may occur as a result of stress formation via steep thermal gradients between the metal cavity and bulk die. Heat flow through the mold accompanied by constrictions in material expansion or contraction governs the magnitude of thermomechanical stress at the casting surface. Latticed cooling channel inserts, which can be readily tailored through additive processes, are a promising remedy for the failure of casting dies through the redistribution of thermal stresses formed from high temperature gradients, offering distinct advantages in HPDC. Conductive heat transfer simulations with boundary conditions representative of aluminum die casting were performed on select lattice geometries to determine their thermal dissipation efficiency. Results from FEA modeling offer critical insights into the thermal conditions and behavior experienced by the die using this novel technology.
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