KANWAY’s core technology will support your HPDC industry.
Failure Mode Analysis of High Pressure Die Casting (HPDC) Molds
Applied to HPDC MOLD
Types of Damage and Proportion
Causes
Countermeasures
Process Management
Thermal Fatigue cracking
1.Repeated heating and cooling of the mold surface.
2.Thermal fatigue tensile stress generation.
3.Grain boundary degradation due to high-temperature oxidation.
4.Crack propagation due to tip effect
5.Reduction in Cr content due to high temperature.
6.Decrease in mold hardness at high temperatures.
1.Control of die casting conditions.
2.Management of mold surface temperature.
3.Selection of steel with high toughness.
4.Heat treatment ensuring high toughness.
5.Low-hardness diffusion-type nitriding treatment.
6.Control of mold release agent spray volume.
1.Mold cooling design.
2.Steel material.
3.Heat treatment.
4.Die casting process.
5.Diffusion-type. Nitriding treatment.
6.Selection and use of mold release agents.
Seizure / Scuffing
1.Friction Between High-Temperature Molten Aluminum and Hot Mold.
1.Lower mold temperature.
2.Reduce aluminum melt temperature.
3.Apply surface treatments (nitriding or coating).
1.Mold cooling design.
2.Mold melt flow path design.
3.Aluminum melt temperature control
4.Surface treatment
Erosion
1.Physical Friction Between High-Speed Aluminum Flow and Mold Steel.
1.Reduce aluminum temperature and flow speed.
2.Apply surface treatments (coatings).
1.Mold shape design.
2.Surface treatment.
Corrosion
(Aluminum alloy wheellow mold)
1. Chemical Intermetallic Compound Formation Between High-Temperature Aluminum Melt and Mold Steel.
1.Nitriding treatment.
1.Mold cooling design
2.Nitriding treatment
Cavitation
1. The air inside the mold cavity cannot be promptly expelled due to the high-speed flow of the aluminum melt. As a result, it becomes highly compressed, generating localized high temperatures that cause oxidation at the grain boundaries on the surface of the contacting tool steel, leading to grain boundary peeling.
1.Change the flow direction of the melt.
2.Reduce the flow speed of the aluminum melt.
1.Mold design
2.Flow simulation analysis of the aluminum melt
Wear
1.Uneven Thermal Expansion and Friction Between Core, Cavity, and Slide Due to Heating.
1.Mold cooling design.
2.Nitriding treatment (with different hardness settings).
1.Mold design.
2.Nitriding treatment
Corrosion Resistance Test of KW-NT Series
KW-NT has significant effects on the damage of HPDC molds: Corrosion Resistance Test of KW-NT Series
