Bimetallic dies with direct metal-deposited steel on Moldmax for high-pressure die casting application

In high-pressure die casting, cooling time greatly affects the total cycle time. As thermal conductivity is the main governing factor, a higher thermal conductive die material allows faster extraction of heat from the casting, thus resulting in shorter cycle time and higher productivity. This paper presents a novel approach to replace a conventional steel die by a bimetallic die made of Moldmax copper alloy coated with a protective layer of steel using laser cladding technology, direct metal deposition on the cavity surface for high-pressure die casting of aluminum alloys. Study includes the investigation of suitable steel layer thickness on Moldmax substrate in terms of porosity, hardness, presence of copper content, and copper particle. Results obtained from the scanning electron microscope and energy dispersive spectroscopy display a metallurgicallly sound and fully dense steel layer on copper alloy. Results of finite element heat transfer analysis also show that bimetallic die offers superior thermal performance compared with monolithic steel die.