In-service performance of iTherm® piston
A single body iTherm® piston with an innovative Internal Cooling System presents an optimum solution for reduction of cycle time in HPDC and improved in-service life.
iTherm® system provides highest cooling effectiveness while improving: productivity, cast part quality, piston durability.
This tip is a critical component of the shot end for HPDC, where other cooling solutions on the market involve complicated multi-piece assemblies and often Beryllium-Copper (BeCu) alloys. The HTS iTherm® shot tip is a single piece tip made of hardened tool steel, with a tempered steel ring providing a wear point to extend the service life of both the shot tip and the shot sleeve. For an average size shot tip (~100mm in diameter), a BeCu tip can be expected to last 4,000-7,000 shots. An iTherm® shot tip of the same size can be expected to last 50,000-80,000+ shots, with the rings lasting 20,000-30,000 shots.
Shown below, an iTherm® shot tip still in operation after 91,000 shots and 3x ring changes (every 30,000 shots).
It has been known for a long time that steel tips last much longer than BeCu tips, but many still use BeCu to improve the cooling capacity of the tip near the biscuit. With iTherm® tips, the conformal cooling of the steel allows the heat removal rate to exceed that of BeCu tips. This means that die casters finally have a solution that allows for maximum component lifetime AND maximum cooling power. On average, die casters that implement an iTherm® shot tip save 7-15% of cycle time on systems limited by biscuit cooling. Further cycle time reductions can be achieved by implementing conformal cooling on shot blocks and die cores or cavities.