Understanding Conformal Cooling in the Diecasting of Aluminum Alloys

Heat transfer and stress distribution are studied using computational fluid dynamic and structural simulation for a conformal cooling die insert made of Maraging M300 steel by selective laser melting. The phase transformation of cooling water is studied to understand the cooling effects and stress concentration on die life. The results of simulation are validated in production. The failure of the die insert has been revealed a result of enhanced stress concentration and corrosion directly related to the formation of vapor in the conformal cooling channel.