Die Temperature Control

Die Temperature: an important process variable
Die temperature is an important variable in the Die Casting process which impacts on both the quality of the castings and the optimum production rate. Where temperature is too low, cold shots, short shots, porosity or excessive contraction may occur. Where it is too high, then hot tearing, warping, blisters, porosity and other problems may result.

Better control of die temperature can significantly reduce the incidence of rejected parts and increase the production rate per hour.

The solution from HotFlo!
Die temperature will vary from point to point within a die and it will also vary with time, making it a very complex variable. HotFlo! have developed a suite of compatible equipment which cuts through this complexity. You now have readily available a rugged, reliable, easy-to-use system to enable your Die Casting plant to move up to the next level of die temperature control.

The two key components of the system are a 4-Zone Die Temperature Controller and a 4-Zone Die Cooling Module, which can be connected to any die in your factory to monitor and control the critical temperature profiles required to make good castings. The result is:

Clear visibility of temperature in critical locations
Better understanding of the effects of temperature variation
Automatic control during production
High power cooling where needed
Additional heat input where required
Die pre-heating before setting

Display of Temperature
The big bright temperature display gives you a new window into the heart of the Die Casting process. Each zone of the Controller can be independently directed to either the 'Fixed' or 'Moving' die half. You can easily determine if the die heating system is up to the start temperature, if the coolant is functioning correctly and what temperatures give consistently good castings.

Control of Cooling
The 4-Zone Controller gives you a new level of monitoring and control over all methods of die cooling:
Water Cooling is used for high power cooling, or where small coolant lines must be used. Ideal for thick wall castings, cavity cores and moving slides. Automatic control is achieved with the Die Cooling Module.
Oil Cooling is used where moderate cooling power is sufficient or where extra heat is required in cavity inserts. Any type of oil cooler can be used and performance is monitored by in-tool temperature sensing.
Air Cooling is used for low power cooling, particularly with the high die temperatures of low pressure, permanent mold and gravity Die Castings. Automatic control is maintained with the Die Cooling Module.

Control of Heating
Electric heating is efficient, compact and powerful, and there are three good reasons to use it inside your Die Casting dies:

Die Pre-Heating:
You can get your dies up to temperature before you set them in the machine by simply plugging them into the power source. This will maximise your machine availaibility and virtually eliminate "warm-up shots" and their costly waste. Hotflo can help you with how to do this.

Maintaining Temperature:
If your production is halted for any reason, electric Die Heating Plates will switch on and keep your die at its minimum set temperature. By keeping the temperature of the fixed and moving halves equal, dowel pin jamming is eliminated.

Hot Sprue Kits:
The 4-Zone Controller gives you another level of control for your hot sprue system, including temperature of sprue tips, runner inserts and cavities.

Oil-Based Temperature Controllers
For many dies, an excellent solution to temperature control is to use a HotFlo 4-Zone or 8-Zone Die Temperature Controller in conjunction with an Oil-Based Temperature Controller.

The oil lines are positioned in the die blocks, the bolsters or the outer edges of the cavity inserts. They provide the heating source for the dies during start-up or during a production stoppage. They are usually controlled by measuring the temperature of the oil as it flows back to the unit.

The water cooling lines are positioned in the die cavity inserts, near the cavities or the runners. They provide the high powered cooling required for high production rates. The water flow is controlled by the thermocouples in the die: one for each cooling line.

This combination of coolant fluids, oil and water, in different zones of the die, takes advantage of the thermal properties of each fluid, and maximises production rate and product quality.