A wide range of materials and coatings were provided as in-kind contributions to this project by manufacturers and suppliers. Bohler Uddeholm and Kind provided steels, BrushWellman provided copper-based alloys , CMW and Kulite provided tungsten-based alloys, CSM (an H.C. Stark company) provided molybdenum-based alloys, Allvac provided nickel-based alloys and Dynamet provided titanium based alloys. Coatings were provided by Badger Metals, Dynamic Metal Treating, IonBond, Balszers and Phygen. In addition, in-plant evaluation of some of these materials under production conditions was undertaken by Metaldyne (previously Lester Die Casting) and Saint Clair Die Casting. Valuable technical support and advise were received from DCD Technology on tooling issues.
ABSTRACTDie materials for aluminum die-casting need to be resistant to heat checking, and have good resistance to washout and to soldering in a fast flow of molten aluminum. To resist heat checking, die materials should have a low coefficient of thermal expansion, high thermal conductivity, high hot yield strength, good temper softening resistance, high creep strength, and adequate ductility. To resist the washout and soldering, die materials should have high hot hardness, good temper resistance, low solubility in molten aluminum and good oxidation resistance. It is difficult for one material to satisfy with all above requirements. In practice, H13 steel is the most popular material for aluminum die casting dies. While it is not an ideal choice, it is substantially less expensive to use than alternative materials. However, in very demanding applications, it is sometimes necessary to use alternative materials to ensure a reasonable die life. Copper-base, nickel-base alloys and superalloys, titanium-, molybdenum-, tungsten-base alloys, and to some extent yttrium and niobium alloys, have all been considered as potential materials for demanding die casting applications. Most of these alloys exhibit superior thermal fatigue resistance, but suffer from other shortcomings.The current project conducted a systematic evaluation of potential die materials and diffusion coatings available commercially. The first group of materials evaluated were advanced die steels developed in the late 90's and marketed since 2000. Two representatives of this group are the BohlerUddeholm Dievar and the Kind Co. TQ1. In