ADDITIVE MANUFACTURING OF COMPONENTS FOR IN-DIE CAVITY USE, SUITABLE TO WITHSTAND ALUMINIUM HIGH PRESSURE DIE CASTING (HPDC) PROCESS CONDITIONS

Abstract

This research examines the suitability of Additive Manufacturing (AM) for manufacturing dies used in aluminium high pressure die casting. The study was guided by the following objectives:

• The reviews of applicable literature sources that outline technical and application aspects of AM in plastic injection moulds and the possibilities of applying it to high pressure casting die. • To introduce AM grown die components in die manufacture. Further, to develop a methodology that will allow industry to apply AM technology to die manufacture. • Revolutionise the way die manufacture is done. The potential for AM technologies is to deliver faster die manufacture turnaround time by requiring a drastically reduced amount of high level machining accuracy. It also reduces the number of complex mechanical material removal operations. Fewer critical steps required by suitable AM technology platforms able to grow fully dense metal components on die casting tools able to produce production runs. • Furthermore, promising competitive advantages are anticipated on savings to be attained on the casting processing side. AM technology allows incorporation of features in a die cavity not possible to machine with current machining approaches and technology. One such example is conformal cooling or heating of die cavities. This approach was successfully used in plastic injection mould cavities resulting in savings on both the part quality as well as the reduction on cycle time required to produce it (LaserCUSING®, 2007). AM technology has evolved to a point where as a medium for fast creation of an object, it has surpassed traditional manufacturing processes allowing for rapidly bridging the gap between ideas to part in hand. The suitability of the AM approach in accelerating the die manufacturing process sometime in the near future cannot be dismissed or ignored. The research showed that there is promise for application of the technology in the not too distant future. In the South African context, the current number and affordability of suitable AM platforms is one of the main stumbling blocks in effecting more widespread applied research aimed at introduction of the technology to die manufacture.