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Way to improve die life, Huizhou Die Casting Die Factory

What are the methods for die casting companies to improve the service life of dies

1. Preheat the die casting die before operation

2. Intermediate stress relief tempering can increase the service life of the die by 1~2 times. Intermediate stress relief tempering shall be carried out before cracks appear, and the tempering temperature shall be 30~50 ℃ lower than the original tempering temperature

3. Shot peening

Shot peening can form compressive stress on the surface of the mold forming, close the fine cracks on the surface and prevent them from expanding, delay the formation and expansion of thermal fatigue cracks, and thus improve the life of the mold

4. Nitriding treatment

Nitriding can improve the wear resistance and turbidity resistance of the die casting die, and prevent the adhesion of aluminum, copper and other die castings. After nitriding, the cold and hot fatigue resistance of the die can be improved by proper tempering treatment to reduce the brittleness of the nitrided layer

5. Carboboriding

The working parts of the aluminum alloy die-casting die made of 40Cr steel can not only have extremely strong surface strength, good red hardness and oxidation resistance, but also have a deeper layer and a gentle hardness distribution gradient after carbonboronizing. The service life of the die can be increased by 3 to 4 times

6. Mold pretreatment

The rapid homogenizing spheroidizing annealing process can effectively solve the size sensitivity of the uneven structure of the die casting die steel

7. Optimizing die structure and reasonable die casting process

When designing the die casting die, it is necessary to comprehensively analyze the casting structure, be familiar with the operation process of the die casting machine and the adjustable range of process parameters, analyze the filling characteristics of the molten metal, and optimize the die casting die structure; Select reasonable process parameters such as injection ratio, filling speed and pouring temperature to prolong the service life of the die casting die

In the process of die casting production, die casting dies sometimes fail. The causes of failure are mainly caused by the following three aspects. The following is a brief introduction of Lianzhou Hardware Die Casting Factory:

1. Fragmentation failure

Under the action of the pressure injection force, the die casting die will initiate cracks at the weakest part, especially the scribing marks or electric machining marks on the molding surface of the die are not polished, or fine cracks will first appear at the corners of the molding. When there are brittle phases or coarse grains at the grain boundary, it is easy to break. However, the crack propagates rapidly during brittle fracture, which is a very dangerous factor for the fracture failure of the die. For this reason, on the one hand, all scratches and electric machining marks on the mold surface must be polished, even if they are in the gating system, they must also be polished. In addition, the die materials used shall have high strength, good plasticity, good impact toughness and fracture toughness

2. Corrosion failure

Common die-casting alloys include zinc alloy, aluminum alloy, magnesium alloy and copper alloy, as well as pure aluminum die-casting. Zn, Al and Mg are more active metal elements, and they have good affinity with mold materials, especially Al is easy to bite. When the die hardness is high, the corrosion resistance is good, while if there are soft spots on the formed surface, the corrosion resistance is not good

3. Thermal fatigue cracking failure

During the die casting production, the die casting die is repeatedly subjected to the effect of cold and heat stimulation, the forming surface and its interior are deformed, and the mutual drag causes repeated thermal stress, leading to structural damage and loss of toughness, leading to the appearance of microcracks, which continue to expand. Once the crack expands, molten metal is squeezed in, and repeated mechanical stress accelerates the crack growth. Therefore, on the one hand, the die must be fully preheated at the beginning of die casting. In addition, the die casting mould must be kept in a certain working temperature range during the die casting production process to avoid early cracking failure. At the same time, it is necessary to ensure that there are no internal problems before the mold is put into production and during manufacturing. In actual production, most die failures are thermal fatigue cracking failures