Thermal Gradient

die details also react badly to hot and cold exposure.

If your feet are in the fire, placing a block of ice on your head will not make you feel better. Yes, on average the temperature you are exposed to is correct. The thermal gradient is the problem. Die casting dies are the same. Molten aluminum at 1200F or more one one side. Cooling water at 80F beneath the surface. H13 splits if the water is closer than 3/4 inch to molten aluminum. The thermal gradient is too high for the material. Water cooling was added to the H13 core pin forming the central shaft hole in the pictured front air conditioning compressor casting. The added water passage was closer than 3/4 inch away from molten metal. The core pin split in three shots. Maraging die steel tolerates a higher thermal gradient. This same water cooled core pin out of maraging die steel did not split. This is probably why conformal cooling details 3D printed out of maraging material achieve higher cooling performance.

Alloy

New alloys underpin innovative automobiles

In the heyday of Detroit, popular cars like a 57 Chevy included a die cast aluminum alloy automatic transmissions. Success leads to wide spead adoption. The aluminum alloy used to make the automatic transmission became the world standard. Die cast aluminum alloy became a commodity listed on the London Metal exchange. The purchasers of 57 Chevy .autos enjoyed the advancement. This is similar to the improvement in human lives that became possible with the creation of metal alloys for making a surgical scalpel. Time marches on. Today, we would not consider using anything but a scalpel made of the best surgical steel alloy. The buying public feel the same way about thier automobiles. The enthusiasic public acceptance of electric automobiles are causing new aluminum die cast alloys to displace the old standards. The brittle corrosion prone old standards are being replaced with ductile aluminum die cast alloys that are strong without heat treat.