THE CUSTOMER
Turkish HPDC Foundry
HTS SOLUTION
iTherm® Die Insert
THE CHALLENGE
Porosity elimination
OUTCOME
57% reduction in porosity volume
Case study overview
Our Turkey-based customer, a specialist in high-pressure die casting for the automotive industry, was facing issues with overheating in one of their inserts, leading to shrinkage porosity in the castings.
Despite trying a conformal cooling insert, they were dissatisfied with its performance and results.
Thermal performance comparison
Using iTherm®, we developed a concept that significantly improved temperature uniformity across the surface. This allowed us to reduce the hotspot temperature by 71°C before spraying and 25°C during the solidification phase.
Die soldering analysis
Conclusion
Lower operating temperatures
particularly during the solidification phase. In conventional designs, the die surface temperature often rises significantly above the critical threshold. With iTherm® inserts, the reduced operating temperatures also lead to a notable decrease in the die soldering effect.
Improved solidification
Enhanced cooling and consistently lower temperatures throughout all phases accelerate alloy solidification, resulting in significantly improved wall formation in the casting.
Improved casting quality
By shortening the solidification time, the iTherm® insert effectively minimizes shrinkage voids, improving overall casting quality.
Lower surface temperatures contributed to better casting quality by reducing the likelihood of thermal defects and ensuring more precise casting dimensions.
Faster cycle times and improved efficiency
Beyond solving the porosity issue, the implementation of the iTherm® insert also delivered measurable efficiency improvements. The customer achieved a reduction in cycle time by 6 seconds, decreasing from 150 seconds to 142 seconds, thereby optimizing production speed.
