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Improving Casting Mold Longevity

Request Number N975998
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Description

IncWell's partner seeks methods to extend the lifespan of molds used for aluminum casting of parts for the automotive industry.

 

Background

The production of aluminum cast parts requires the usage of casting molds. These molds can be used between 90,000 to 100,000 times per year.

 

As the mold is rapidly heated during use, then cools and is used again, the mold experiences

  • heat checking: surface cracks occur on the die due to a large temperature change on every cycle
  • temperature cycle fatigue: surface cracks occur on the die due to a large number of cycles
  • chemical attacks from the liquid aluminum: the aluminum has an affinity for tool steel

 

With a production program lasting 5 years or more, there is a need for casting mold maintainence and replacement during the life of the program. As a result, it is highly desirable to locate a technology capable of greatly increasing the life span of these molds.

 

Key Success Criteria

The successful technology will have:

  • a usable lifespan increase of 2-3x
    • or ideally last the life of the program (5-7 years)
  • no significant cost increase over existing casting technology

 

Possible Approaches

Potential solutions could include, but are not limited to: 

  • Wax die lubricant 
  • Coatings or surface treatments
  • New Tool Steels
  • Advanced Die Surface Monitoring and Cooling Controls

 

Approaches not of interest

None.

 

Preferred Collaboration types
  • To Be Negotiated
Items to be submitted

When responding to this request, please be sure to provide a non-confidential description of the technology or solution you propose along with information regarding your alignment with the Key Success Criteria as well as your desired business relationship with IncWell's partner.

 

Point of Contact
Jonathan Jakischa
Area of Interest
  • Commercial & Industrial Design
  • Manufacturing & Fabrication
  • Molding
Organization
IncWell
Due Date
April 28, 2017
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