Influence of flow rate on the temperature and pressure conditions during die filling

Operating conditions of tools for die casting of aluminium alloys are very exacting. Damages to and defects of tools occur at different locations, above all at the die, which is in a direct contact with the melt or a casting. Any incorrectness in the design and manufacture of a tool, especially in its heat treatment, may essentially accelerate the occurrence of damages. Thermo-mechanical stresses in tools produce fatigue microcracks, which will, along with tool operation, propagate into depth and in width. After a certain time, these damages may result in visible damages to the casting or even in a fatigue failure of the tool or local damages to the die. Numerical simulations using the method of finite elements and simultaneous experimental measurements were performed in order to minimise the occurrence of premature undesired damages and locate hot spots at the tool. Simulations applied to a tool made of material 1.2343 were performed at one of aluminium-alloy products – Support carrier – produced by a co...