An in-situ cooling tube casting method for a sand-cast aluminum thermoforming mold.

Abstract

An in-situ cooling tube casting method for a sand-cast aluminum thermoforming mold is disclosed. The method comprises incorporating at least one cooling tube circuit within a sand mold prior to casting, positioning the cooling tube to form one or more circuits having inlet and outlet ends, and circulating a cooling medium through the cooling tube from before pouring of molten aluminum to completion of solidification. Molten aluminum is then poured into the sand mold and allowed to solidify under continuous cooling.The continuous circulation of the cooling medium prevents thermal distortion, deformation, or melting of the cooling tube due to exposure to molten metal, while also controlling heat extraction and solidification behavior of the cast mold. The cooling tube is formed from a heatconductive material having a melting point higher than aluminum, such as copper or steel.In an embodiment, multiple cooling tube circuits may be provided and, after casting, two or more circuits may be connected externally to form a single circuit with one inlet and one outlet, since the tube ends remain outside the mold while only the intermediate portions are embedded within the casting.The cooling circuits are supported within the sand mold using suitable supports to maintain position during casting. The cooling medium may be water at room temperature or chilled water, with flow rate adjusted according to cooling and shrinkage requirements.The method reduces or eliminates post-casting machining and secondary joining operations for cooling tube installation, thereby simplifying manufacturing and improving thermal performance, dimensional stability, and mold life.