Applying Functionally Graded Materials by Laser Cladding: a cost-effective way to improve the Lifetime of Die-Casting Dies

Abstract

The lifetime and economic methods of improving the lifetime of a die-casting die are key factors for the die-casting industry since the global competition and the competition with other production techniques have increased significantly. The article depicts the approach, technical realization, latest results and process limitations of the INNOGRAD research project. Here, powder-based laser-cladding is applied to combine two materials as a functionally graded material. By applying gradient structures it is possible to fit the material to the predominant type of exposure, resulting in an increase in the lifetime of die-casting dies.

A comprehensive review on recent developments in materials and technological parameters for plasma transferred arc hardfacing process

“…42 Laser cladding-assisted hardfacing technology may be the substitute of PTAHF to improve wear and thermal fatigue resistances and can deposit material by smooth transaction from the substrate to the hardfacing layers. 63,81 Parameters affecting the process…”

An assessment of residual stress mitigation strategies for laser clad deposits

“…Indeed, these processes have been employed across a range of industrial sectors, including the nuclear, automotive, petrochemical and aerospace industries. For example, laser cladding has been used to repair turbine blades in the aerospace industry, 1–3 to repair moulds used in the plastics industry, 4 in rapid prototyping, 5 to repair die-casting dies, 6 in the repair of heavy mining equipment, and for the reclamation of pump components in the oil recovery and refining industry.…”

Estimation of the Thickness and the Material Combination of the Thermal Stress Control Layer (TSCL) for the Stellite21 Hardfaced STD61 Hot Working Tool Steel Using Three-Dimensional Finite Element Analysis

“…3(a)의 최대 열유량(Q a,max )은 4,000 kW/m 2 이다. (6) 열전달해 석시 기저부의 바닥면과 측면들에는 Fig. 3(a (7) 식 (2)의 혼합법칙을 활용한 유효 비열 산 출식로부터 열응력제어층의 비열을 계산하였다.…”

“…(7) 열응력제어층의 유효 열전도도는 맥스웰(Maxwell) 모델을 이용하여 식 (3)과 산출하였다. (8) Table 3 Thermal properties and thermal expansion coefficients of STD61 and Stellite21 (6) Material ρ (kg/m 3 ) C p (J/kg o C) k (W/m o C) α (10 -6 /K) Fig. 10 과 같은 열응력제어층의 재 료 혼합비 및 두께에 따른 경계부 A 와 B 에서 발 생하는 주변형률 단차 변화를 도출하였다.…”

“…열응력제어층과 하드페이싱부의 두께의 합은 2 mm 가 되도록 설계하였다 (6). 이 연구에서 적용된 열응력제어층의 STD61 체적비율과 두께범위는 각 각 25~ 75 % 와 0.5 mm ~ 1.5 mm 이다.…”