Experimental and numerical analysis of failures on a die insert for high pressure die casting

Markežič, Rok; Naglič, Iztok; Mole, Nikolaj; Šturm, Roman

doi:10.1016/j.engfailanal.2018.09.010

Cited by 17 publications

(8 citation statements)

References 29 publications

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“…Analysis of the insert is carried out in the die casting tool, for carrying of AlSi9Cu3Fe. The numerical and experimental analysis is carried out for the insert in which numerical analysis is carried out by a new procedure, which combines MAGMA and CalculiX and during experimental analysis, hardness measurements, light microscopy, SEM analysis and XRD pattern are obtained in order to examine the insertion in the die casting process of AlSi9Cu3Fe [3]. Machine learning and numerical simulation are carried out to optimize the solidification in die casting that is product quality by obtaining initial and wall temperatures.…”

Section: Literature Review and Problem Statementmentioning

confidence: 99%

Numerical investigation on crack analysis of H13 fixed die and structural analysis of moving die with two different materials

Abdulhadi

2021

EEJET

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Die casting is forcing molten metal into a mould with high pressure. Die casting has two dies namely moving die and fixed die where the moving one will move over the fixed die. Die casting is majorly used for high-volume production. This paper focused on the physical phenomenon of die casting for two dies (moving die and fixed die) using two different alloy materials with variable material chemical compositions. The numerical analysis is carried out for the die casting process to determine the crack formation zone by temperature distribution and structural analysis by stress-strain relationship. The numerical analysis is carried out for both the dies. The fixed die is analyzed with an H13 tool steel material with two moving die materials as aluminum alloy (A356) and magnesium alloy (AZ91D). Both the dies (fixed and moving) were designed by using design software and meshing is carried out followed by analysis using the analysis software. The physical parameter for the dies is applied that is temperature distribution is carried out by applying a temperature of 850 °C and 650 °C over the fixed die for aluminum and magnesium alloy, respectively. Structural analysis is carried out for the moving die with a load of 1,000 N for both aluminum and magnesium alloys with 1000 number of iterations. The results from the numerical analysis are derived and analyzed for both temperature distribution and structural analysis. The crack formation zone is found out by means of temperature gradient and the stress-strain relationship is found out by means of structural analysis. From the results, it was concluded that the crack zone is obtained at 1.22E-10 °C/mm and 6.856E-14 °C/mm of thermal gradient and structural analysis in terms of maximum stress of 446.94 MPa and 448.52 MPa for aluminum and magnesium alloys, respectively.

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Section: Literature Review and Problem Statementmentioning

confidence: 99%

Numerical investigation on crack analysis of H13 fixed die and structural analysis of moving die with two different materials

Abdulhadi

2021

EEJET

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“…Therefore, the cooling speed decreased as well as the fraction of the hardening phases, which resulted in lower hardness. Both deposits are characterized by high surface hardness, which, according to Markežič [5], may lead to decreases in the density and depth of thermal fatigue cracks. Table 2 shows the corrosion characteristics measured and calculated by Tafel analysis valid for the base metal -Dievar and weld deposits made by particular technologies.…”

Section: Abrasive Wear Testmentioning

confidence: 99%

“…Jhavar [1] analyzed in detail the causes of dies and molds failure, while Anderson [2] conducted a similar study for extrusion tools and moreover Ebara [3] and Chander [4] for forging dies. Subsequently Markežič [5] focused on the HPDC process and considered the main mechanisms of mold failure: soldering (or die sticking), corrosion, erosion, thermal fatigue and cracking. Soldering is the bonding of the cast material to the mold surface and is the result of simultaneous metallurgical and mechanical bonding.…”

Section: Introductionmentioning

confidence: 99%

“…Such a thermal load regime of the mold insert can also lead to oxidation of the surface layers and change of the microstructure [8] and hence the microhardness of the mold insert surface. According to Markežič [5], an adequate hardness of the mold functional surface is an essential characteristic that helps prevent the initiation and spread of wear and damage mechanisms. Subsequently, suitable technologies for the mold renovation were sought -local refilling of the material, which is missing after part deep removal of the material with cracks.…”

Section: Introductionmentioning

confidence: 99%

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The Corrosion and Wear Resistance of Laser and Mag Weld Deposits

Guzanová¹,

Džupon²,

Draganovská³

et al. 2020

Acta Metall Slovaca

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The paper focuses on the possibility of HPDC molds restoration for aluminium casting by laser and MAG weld cladding with a welding wire of the same grade like the base material. A chemical analysis of the weld deposits showed a decrease in the content of some elements in the MAG deposit due to the higher thermal input to the weld bath. The lower heat input of laser welding has resulted in a higher incidence of fusion defects lack between the weld deposit and the base material. Thermal conditions during welding affected hardness of weld deposits and their abrasive resistance as well. The resistance of materials against dissolution when immersed in AlSi8Cu3 alloy was similar for both deposits and the base metal.

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“…The erosion is the result of soldering and the impact of high-velocity molten aluminum alloy at the same location [11]. The erosion is marked by a loss of material from the die surface and the decline of surface hardness [12,13]. Additionally, the erosion is controlled by temperature, velocity, die surface modeling, and impact angle.…”

Section: Introductionmentioning

confidence: 99%

Research on the Corrosion Behaviors of Austenitic Steel in Molten Aluminum Alloy

Bai

Yang

et al. 2022

Coatings

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Die corrosion has been a concern during aluminum alloy die casting. The casting parameters play a significant role in causing corrosion, such as the temperature of the aluminum alloy melt and working time. In order to study the effect of temperature and working time on dynamic corrosion behaviors, SDHA steel was stirred in molten ADC12 aluminum alloy at 650–800 °C. The corrosion morphology and corrosion product were investigated through X-ray diffraction (XRD) and scanning electron microscope (SEM) observations. The results show that the matrix reacts with aluminum alloy to form an Al8Fe2Si phase at experimental temperatures. The growth activation energy of the Al8Fe2Si phase is 89 kJ/mol. The dynamic corrosion rate rises with increasing temperature and holding time. The most serious corrosion was found when the experimental temperature reached 800 °C, which is closely related to the peeling of matrix and the formation of Al8Fe2Si at the grain boundary. Besides, the vanadium carbides in the matrix act as barriers to hinder the diffusion of Al and Si atoms effectively.

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Experimental and numerical analysis of failures on a die insert for high pressure die casting

Cited by 17 publications

References 29 publications

Numerical investigation on crack analysis of H13 fixed die and structural analysis of moving die with two different materials

Numerical investigation on crack analysis of H13 fixed die and structural analysis of moving die with two different materials

The Corrosion and Wear Resistance of Laser and Mag Weld Deposits

Research on the Corrosion Behaviors of Austenitic Steel in Molten Aluminum Alloy

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