APPLICATIONS » HPDC

ADDITIVE MANUFACTURING – THE NEXT DIMENSION IN HIGH PRESSURE DIE CASTING TOOLING

For decades we have been recognized as a global leader in the manufacture and the supply of tool steel, as a result we understand the challenges that our customers face in the high pressure die casting industry. Customer intimacy and technical understanding is a major factor when developing successful solutions with our partners.

Our attention to detail goes far beyond the design of the tool. Our additive manufacturing experts develop printing parameters specifically optimized to suit our range of high performance high pressure die casting materials, giving our customers unique solutions with superior results.

Unique tools require unique solutions. Working together with our customers, using our state-of-the-art additive manufacturing and materials know how, we develop tailormade AM solutions optimized specifically for high pressure die casting.

Your trusted AM partner

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OPTIMIZED DESIGN

AM expertise paired with extensive high pressure die casting know-how ensures we deliver the best possible tooling solutions to our customers. We support our customers through a detailed consultation process to develop the right solution for the right application, using state-of-the-art tools to support the manufacturing process from initial concept to functional parts. Where needed our high pressure die casting experts can help our customers re-design tools according to the exact requirements of their application.

Our data driven approach to cooling channel design analyses processing parameters and mechanical loads to develop detailed computer models and process simulations. This method of optimizing thermal management is essential to ensure the right balance between efficient cooling and the mechanical performance of the tool.

This process goes far beyond regular conformal cooling channel design. We understand high pressure die casting.

Failure analysis and process simulation are important key competences. When paired with our AM design and processing know how, we gain a deep understanding of not only the challenges, but how we can best optimize the part in relation to the performance needs of the customer.

 


 

OPTIMIZED PRINTING

We ensure the highest possible quality, reliability and consistency by managing every step of the value chain from powder production to the delivery of the finished part. Whether for a single part order or series production, our internal quality systems ensure we meet your requirements every time. We use state-of-the-art tools to continually improve and refine our internal printing processes. Design of Experiments, Statistical Process Control, and Process Monitoring form the basis of our methodology. Continued innovation from our AM and materials groups ensures we deliver superior material properties in the most demanding applications. As a result, our customers can put parts into service with the highest degree of confidence.

We understand the interactions between laser and material. This deep understanding of AM and high pressure die casting allows customers to add value to their business and realize competitive advantage.


 


 

OPTIMIZED POWDER

Our long history of developing materials for the high pressure die casting industry, means the powders we use are of the highest quality and deliver superior tool life.

BÖHLER W360 AMPO is our premium grade for high pressure die casting applications. This proprietary grade has been designed to outperform many traditional tool steels such as 1.2709 (Maraging 300), 1.2343 ESR (H11) and 1.2344 ESR (H13).

 

IN SHORT

  • High temper back and hot wear resistance
  • Recommended hardness in use 48 – 56 HRC
  • High toughness
  • Designed for high demanding tooling applications like high pressure die casting and reinforced plastics

 


 

FAILURE ANALYSIS

Our support does not end with the delivery of additive manufactured inserts. It goes far beyond that. Every tool has a certain lifetime and fails at some point. We analyse and examine your failed tool inserts to determine the cause of damage. For example, a crack can have many different causes. Only those who know the cause can take the necessary action to extend the service life and to solve the problem.

Cracks that have occurred due to an incorrect channel design, because the customer requirements were not taken into account

Left: macroscopic image of cracks in the tool with scaling in the cooling channel (top) and microscopic image of cracks in the LOM (bottom)

Right: microscopic image of a crack (top) and simulation results (bottom)

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HPDC TAILORMADE SOLUTIONS

OPTIMIZED DESIGN. OPTIMIZED PRINTING. OPTIMIZED POWDER. OPTIMIZED FOR YOU.

Our three-pillared approach to additive manufacturing has shown to deliver significant performance improvements to our high pressure die casting customers across a range of applications, such as sliders, sub-inserts, sprues, and distributors (and distributor rings).

 


 

PRINTING & POST-PROCESSING

As a global steel and technology leader, we offer the full suite of production techniques and services throughout the value chain, supporting and driving innovation and development based on lengthy experience around materials and processing. Starting from the alloy development and metal powder production, to design and manufacturing and including post-processing. We offer the end-to-end solutions to reduce waste and mitigate risk in the supply chain with the goal of being your trusted and reliable business partner. We deliver tailormade solutions from concept to component.

Metal Powder additive manufacturing metal powder
additive manufacturing Parameter Development Parameter Development
Design/Simulation additive manufacturing Design/Simulation
additive manufacturing Additive Manufacturing
Heat Treatment additive manufacturing Heat Treatment
additive manufacturing Machining Machining
PVD Coating additive manufacturing PVD Coating
additive manufacturing Inspection/Testing Inspection/Testing

 

HIGH PRESSURE DIE CASTING PRODUCTS

AM single-body distributors & distributor rings
AM single-body distributors & distributor rings

HPDC BROCHURES

GENERAL RECOMMENDATIONS FOR ADDITIVE MANUFACTURED HPDC TOOLING INSERTS

 


 

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