Gas-Cooled Tungsten Insert Die for Cylinder Head Casting
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Solution Overview
Problem
Existing casting technologies for cylinder heads in internal combustion engines face inefficiencies due to the use of water-cooled insert dies, which suffer from reduced production efficiency, thermal conductivity issues, and damage from oxide deposits, necessitating a water-free cooling solution.
Innovation Solution
A casting device employing an insert die made from high thermal conductivity materials like tungsten, molybdenum, or tungsten carbide with a gas passage, preferably spiral or meandering in shape, for forced cooling using gases like air, nitrogen, or carbon dioxide, eliminating the need for water and enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water is used as cooling medium in the cooling passage, then cooling effect is achieved, but production efficiency decreases due to air removal requirements and thermal conductivity limitations
Solution Approach 1:
The invention replaces water-based hydraulic cooling with gas-based pneumatic cooling. The cooling passage is designed to allow gas flow from inlet to outlet, eliminating the need for air removal valves and associated production delays while maintaining effective cooling of the insert die.
Solution Approach 2:
The invention changes the physical state of the cooling medium from liquid (water) to gas (air or other gases). This parameter change eliminates issues related to water's thermal conductivity limitations and oxide deposit formation, while improving production efficiency by removing air venting requirements.
2Temperature
If water is used as cooling medium, then cooling is achieved, but oxide deposits form on the inner wall surface reducing thermal conductivity
Solution Approach 1:
The invention switches from liquid water cooling to gas cooling. Gas cooling eliminates the formation of oxide deposits on the cooling passage inner walls, maintaining consistent thermal conductivity and reliable cooling performance over time without the degradation issues associated with water-based systems.
Solution Approach 2:
The invention uses gas (such as air or inert gases) as the cooling medium, creating an environment that does not promote oxide formation on the cooling passage surfaces. This maintains the thermal conductivity of the passage walls and ensures consistent cooling effectiveness.
3Ease of operation
If air ventilation valve is installed to discharge air, then air removal is achieved, but device complexity increases
Solution Approach 1:
The cooling passage is designed as a simple gas flow path without air ventilation valves or complex air removal mechanisms. Gas naturally flows through the passage from inlet to outlet, automatically carrying air bubbles away without requiring additional components or complex control systems.
Solution Approach 2:
The gas cooling system is self-service in that the gas flow automatically removes air from the system without requiring external air venting mechanisms. The gas flow itself performs the air removal function, eliminating the need for separate air ventilation valves or complex air management systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides effective cooling of the insert die, maintaining structural density and strength of the combustion chamber, while avoiding the drawbacks of water-cooled systems, such as reduced production efficiency and thermal conductivity limitations.
Implementation Method 1
a gas passage (93) is formed in the insert die (90) so as to allow the cooling medium to flow therein. The cooling medium causes forced cooling of the insert die (90).
Implementation Method 2
the insert die is a sintered product made from a powder whose main material contains at least one of tungsten, molybdenum and tungsten carbide
Data Source
AI summary
A casting device includes a mold provided with an insert die, a molten metal supply device for supplying molten metal into the mold, and a gas supply mechanism for supplying a gas, which is used for forced cooling, to the insert die. The insert die is made of tungsten having a thermal conductivity significantly higher than that of die steel. The insert die has a spiral or meandering gas passage therein. The spiral or meandering gas passage has a passage length much longer than a straight passage.