New materials failure analysis in die casting mold manufacturing

High pressure die casting is a technique in which liquid metal is pressed into multi-piece reusable molds over short cycle times. Unlike other casting methods, the action of the filing will not affect the weight; hence, the casting processes occurs due to high-speed fluid flows, and at the end of this process, this kinetic energy is converted into heat and pressure energy. Accordingly, high-precision and thin-walled castings of high quality and with sharp corners and edges are produced under special conditions using this die casting method. The majority of the non-ferrous alloys processed by die casting consist of aluminum, magnesium, and zinc. During injection of aluminum into a mold, the die casting is under high thermal and mechanical stresses. Principally, the lifetime of a casting mold depends on the choice of the mold material characteristics, as well as its chemical composition, method of manufacture and thermal operations. Thermal stresses are created by temperature changes, which may cause damage in the structure of the mold material. This type of damage, which appears as tiny cracks in the outer surface, is due to temperature changes. Deep cracks gradually grow and create cracks as gaps. The damage due to cracks plays a critical role in the lifetime of the die-casting mold. In die casting molds, heat-checking is the typical failure mechanism. Optimizing the parameters that decrease this failure venture should be considered during designing and heat treating steels. This research is investigated properties of the traditional materials 1.2343 (X38CrMoV5-1) H11and 1.2344(X40CrMoV5-1)H13 and the new steels (Dievar & Toloox) when applied to the Die Casting mold specimens, after different experimental cycles. Also, microstructures of the mention materials were analyzed by Light Optical Microscope and Scanning Electron Microscopy (SEM) test. chrome-molybdenum-silicon-vanadium steel, have good hardening ability in oil and air. Therefore, the hot-work steels have considerable toughness and plastic attributes through both regular and higher temperatures. So, it is a good traditional die casting material. However, other special die steel, such as Dievar, is a particularly developed steel grade; Dievar has good heat-checking and gross cracking resistance as a result of both high toughness and good hot strength. An additional material, a new pre-hardened tool steel known as TOOLOX 44, exhibits control of the failure described above by optimizing the parameters of impact toughness that could reduce the heat-checking failures. The issue of diversity in heat treatments is resolved by TOOLOX 44.