MAGMASOFT® was used to confirm the effects of this change. As expected, the filling pattern of the water cooled die was not significantly different from that of the air cooled die. The water cooled die also produced similar trends in the shrinkage, but up to 30 % shorter cooling times compared to air cooling. By reducing the solidification time, the mechanical properties of the combustion chamber area could be increased through a finer microstructure.
In conclusion, changing the cooling medium from air to water, a similar level of casting quality could be achieved. At the same time the production costs were reduced and the mechanical properties, especially in the combustion chamber, were improved.