Revolutionary Hybrid Tool Insert Boosts Die Casting Efficiency
A groundbreaking collaboration between Fraunhofer Institute for Laser Technology ILT, MacLean-Fogg, and Toyota has resulted in a revolutionary hybrid tool insert for the transmission housing of the Toyota Yaris Hybrid. This innovation addresses the challenges faced by traditional die casting molds in meeting the demands of heavily loaded tools with complex cooling structures and short development cycles.
The process chain developed holds immense potential for broader applications in industries requiring such tools. Traditional die casting molds often struggle due to issues like cracking, thermal distortion, and reduced durability in large-format additive builds. To overcome these limitations, Fraunhofer ILT developed a state-of-the-art gantry-based, five-laser PBF-LB/M machine with a substantial build volume of 1,000 x 800 x 350 mm³.
The project, led by Niklas Prätzsch, head of LPBF process technology at Fraunhofer ILT, combined a new tool steel, L-40, engineered by MacLean-Fogg specifically for additive manufacturing. This steel delivers high hardness, tensile strength, and notched impact strength with a lower tendency to crack. The tool insert integrates near-contour cooling channels, significantly lowering thermal loads and extending service life by up to four times compared to conventional H13 molds.
This collaborative effort marks a new era in die casting mold production. The results point to conformal cooling reducing wear, extending tool life, and shortening lead times. As the automotive industry faces increasing cost pressures and a shift toward electromobility, requiring larger, more robust, and thermally resilient tools, this innovation comes at a crucial time. The hybrid production approach, combining conventionally manufactured preforms with additively built sections, offers a promising path forward for the industry.
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