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In-Mold Coating in Pressing of Natural-Fiber-Reinforced Salt Cores for High-Pressure Die-Casting Applications

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Proceedings of the Munich Symposium on Lightweight Design 2021

Abstract

High-pressure die-casting (HPDC) is known as a highly productive manufacturing process for light metals. To overcome geometrical constraints of die-based production processes, lost cores can be applied to enable internal cavities and recesses. As the molten metal is rapidly shot into the die at high-pressure in HPDC, lost cores need to withstand high mechanical and thermal loads. Salt cores are temperature-stable and can be washed out after casting. Thus, they particularly enable complex internal cavities. Reinforcements with flax fibers significantly enhance the stability of casting cores manufactured by compression molding and thus enable a robust processing with less geometrical restrictions in HPDC. This study presents the method of in-mold coating within compression molding utilized to prevent fiber adhesion, infiltration, and degradation within HPDC. The in-mold coated layers investigated within this study were found to successfully prevent both fiber infiltration and adhesion and enabled high quality surfaces. Moreover, a heat insulation effect was detected. From these indications, a sustainable improvement of the technical cleanliness and even the perspective of a fully recyclable fiber-reinforced salt core is conceivable in light metal applications.

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References

  1. Müller, S., Müller, A., Rothe, F., Dilger, K., Dröder, K.: An Initial Study of a Lightweight Die Casting Die Using a Modular Design Approach. International Journal of Metalcasting 12(4), 870–883 (2018).

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  2. Boos, D.: Fiber-Reinforced Salt Cores for High-Pressure Casting Processes. In: 26th National SAMPE Symposium. TUM, Munich (2021). https://doi.org/10.13140/RG.2.2.13797.93926

  3. Technical University of Munich, Chair of Carbon Composites, https://www.asg.ed.tum.de/lcc/aktuelles/article/erfolgreicher-druckgussversuch-mit-faserverstaerkten-salzkernen/, last accessed 2021/11/16.

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Correspondence to Patricia Erhard .

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© 2023 The Author(s), under exclusive license to Springer-Verlag GmbH, DE, part of Springer Nature

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Erhard, P., Boos, D., Günther, D. (2023). In-Mold Coating in Pressing of Natural-Fiber-Reinforced Salt Cores for High-Pressure Die-Casting Applications. In: Rieser, J., Endress, F., Horoschenkoff, A., Höfer, P., Dickhut, T., Zimmermann, M. (eds) Proceedings of the Munich Symposium on Lightweight Design 2021. Springer Vieweg, Berlin, Heidelberg. https://doi.org/10.1007/978-3-662-65216-9_4

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  • DOI: https://doi.org/10.1007/978-3-662-65216-9_4

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  • Publisher Name: Springer Vieweg, Berlin, Heidelberg

  • Print ISBN: 978-3-662-65215-2

  • Online ISBN: 978-3-662-65216-9

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