Development and Characterisation of a New Die-Casting Die Cooling System Based on Internal Spray Cooling

Against the backdrop of climate policy goals and the EU’s aim for a resource-efficient economy, the foundry industry must rethink product range, energy consumption, and production technologies. Light metal casting, which is performed through processes like gravity die casting and high-pressure die casting, requires effective thermal management, which is crucial for optimising mould filling, solidification, cycle times, and part quality. Against this background, this study presents the development and characterisation of a cooling system that completely dispenses with energy-intensive heating/cooling devices. The system is based on a mask shape combined with internal spray cooling. This paper shows the simulation workflow for developing the mould mask and the design of the cooling system and compares the performance with conventional temperature control using channels. In the tests, an 82% higher cooling rate was achieved with Cool-Spray than with conventional temperature control, which was approx. 2.5 mm below the cavity surface. In addition to the more dynamic temperature control, the potential for process control was utilised, and the component quality of the test part was significantly improved compared to conventional temperature control.