Jet cooling Presentation

Presentation :
During the cooling phase, the thermal energy contained inside the metal is transferred to the Die through the contact between the die and the metal, as well as through the pins cooling canals. Precision of the cooling zones as well as the cooling efficiency are essential for the casting quality. A precise thermal regulation of the Die and its elements allows an optimal casting quality, and solves recurrent metallurgical problems.

Presentation :
Thermal exchanges between metal and the Die during the solidification phase are directly influenced by certain parameters. Lifetime of the Die elements, casting quality, as well as process productivity, are all being determined by these parameters.

The use of Jet Cooling is the most effective solution to cool small diameter pins with precision, thus to control material quality problems such as shrinkage and porosity.

Jet Coolings main objective is to master and control the heat transfer in the smallest parts of the Die during the aluminium solidification phase.

General description :

Pin characteristics:
Range : -Pins diameter : minimum diameter of 4mm -Cooling from a drilling diameter of 2mm -Maximum length of the drilling: 200mm (for a drilling diameter of 2mm)

Pin characteristics:

Standard pin

Pin with a 2mm diameter drilling

6

Jet coolers characteristics:

-Jet cooler internal tube : from 1.2/0.85mm to 2.8/2.3mm -Jet cooler watertightness at 20 bar : using oring or threading

Cycle Description:

Jet cooler empty before injection

Top injection

Cooling phase: Pressure of 15/20 bars 20 seconds

Top injection + 3 seconds

Pressurized air to empty out the water

Top injection + 23 seconds

Pin breakage control system

Top injection + 43 seconds

Jet Cooling goals :

Advantages :
Decrease of shrinkages :

Without Jet cooling after 50 injections

With Jet cooling after 5000 injections

The use of Jet cooling in these shrinkage cases allows to maintain a relatively low temperature, thus avoiding any overheating of the pins. The lifetime of these pins which are subject to high thermal constraints is easily multiplied by 5.

Jet Cooling goals:

-Improving the castings metallurgical quality : decrease of porosity

10

Jet Cooling Goals:

Without Jet cooling 11

With Jet cooling

Jet Cooling Goals:

Increasing the pins lifetime:
Average increase : x3 to x5

Cooling optimization :
Spray cooling decrease Spray cooling zones optimization Decrease of the cycle duration

12

Applications :
Exemple 1 : Gear box carter

Microscopic inspection is done on the slice A, with and without the use of Jet Cooling. We can notice smaller-sized grains when using Jet Cooling, thanks to an accelerated solidification phase.

13

Applications :

The use of thermal cameras allow us to point out the eiffiency of the cooling on the pins A and B. These pictures are taken before the spray-cooling phase. The consequence is a 150C saving on the pins. Furthermore, all the zone around the pins equipped with Jet Cooling also benefits from the cooling impact. This impact is of 70C. In this example, the cooling time lasts 10 to 15 seconds.

14

Applications :
Exemple 2 : Clutch carter

15

Applications :
Temperature measurement on the pins equipped with Jet Cooling and before the spray-cooling phase: C

Cooling time in seconds

16

Applications :
Results :
Reduction of the cycle duration as well as the spray-cooling phase duration Improved castings quality Increase of the pins lifetime Decrease of shrinkages and porosities

17

View of the Dies equipped with jet coolers :

18

Ahresty Techno Service Co

Jet cool machine M serie:

4 types of cooling capacities : 20pcs, 40pcs, 60pcs, 100pcs of jet coolers Pressure max 20 bar Flow : max 121 L/min Cooling circuits : 6 max Max number of jet coolers : 100

19

Jet Cooling machine HDK4:

HDK 4-20 system :

- Pressure : 20 bar
- Flow : 20 L/min - Cooling circuits : 4 - Water tank : 60L -Max number of jet coolers : 20

-Advantages : - Closed water circuit - Pin breakage control

20

References :
EUROPE
AE group BMW CIE Vilanova Dacia Renault DGH Fagor Honsel MBK Rencast Renault VW

ASIA
Ahresty group Daihatsu motor Honda motor Isuzu motor Mazda motor Nissan motor Sanden corporation Suzuki Toyota Yamaha

21