Effect of pouring and mold temperatures on hot tearing susceptibility of AZ91D and Mg-3Nd-0.2Zn-Zr Mg alloys

Pouring and mold temperatures are two important parameters during casting magnesium components. The present study examined their influence on hot tearing susceptibility （HTS） of commercial AZ91D and newly developed Mg-3Nd-0.2Zn-Zr （mass fraction, %; NZ30K） magnesium alloys in gravity permanent mold casting condition. The results indicate that mold temperature shows much more significant influence on the HTS of both alloys than pouring temperature whose influence only can be distinguished at low mold temperature （341 K for AZ91D alloy and 423 K for NZ30K alloy）. Hot tearing susceptibility prediction model concerning feeding parameters, grain size and solidification range, is more suitable to estimate the HTS of different magnesium alloys than the model only concerning feeding parameters. In order to achieve better hot tearing resistance, the ranges of pouring and mold temperatures are suggested to be 961-991 K and≥641 K for AZ91D alloy, 1003-1033 K and≥623 K for NZ30K alloy, respectively.

Study on Numerical Simulation of Mold Filling and Heat Transfer in Die Casting Process

A 3-D mathematical model considering turbulence phenomena has been established based on a computational fluid dynamics technique, so called 3-D SOLA-VOF (Solution Algorithm-Volume of Fluid), to simulate the fluid flow of mold filling process of die casting. In addition, the mathematical model for simulating the heat transfer in die casting process has also been established. The computation program has been developed by the authors with the finite difference method (FDM) recently. As verification, the mold filling process of a S-shaped die casting has been simulated and the simulation results coincide with that of the benchmark test. Finally, as a practical application, the gating design of a motorcycle component was modified by the mold filling simulation and the dies design of another motorcycle component was optimized by the heat transfer simulation. All the optimized designs were verified by the production practice.

Preparation of Ni60-WC Coating by Plasma Spraying, Plasma Re-melting and Plasma Spray Welding on Surface of Hot Forging Die

In order to produce the hear-resistant inner layer of hot-forging die, the plasma spraying and plasma re-melting and plasma spray welding were adopted. Substrate material was W6Mo5Cr4V2, including 10%, 20%, 30% tungsten carbide （WC） ceramic powder used as coating material to obtain different Nickel-based WC alloys coating. Micro-structure and micro-hardness analysis of the coating layer are conducted, as well as thermophysical properties for the coating layer were measured. The experimental results show that the coating prepared with 70%Ni60, 30%WC powder has the best properties with plasma spray welding, in which the micro-hardness can achieve 900HV, meanwhile it can improve the thermal property of hot-forging die dramatically.

Simulation of mold filling and prediction of gas entrapment on practical high pressure die castings

Element parameters including volume filled ratio,surface dimensionless distance,and surface filled ratio for DFDM(direct finite difference method)were proposed to describe shape and location of free surfaces in casting mold filling processes.A mathematical model of the filling process was proposed specially considering the mass,momentum and heat transfer in the vicinity of free surfaces.Furthermore,a method for gas entrapment was established by tracking flow of entrapped gas.The model and method were applied to practical ADC1 high pressure die castings.The gas entrapment prediction was compared with the fraction and maximum size of porosities in the different casting parts.The comparison shows validity of the proposed model and method.The study indicates that final porosities in high pressure die castings are dependent on both gas entrapment during mold filling process and pressure transfer within solidification period.

STUDY ON DESIGN TECHNIQUES OF A LONG LIFE HOT FORGING DIE WITH MULTI-MATERIALS

A new design technique for the long life hot forging die has been proposed. By finite element analysis, the reason .for the failure of hot forging die was analyzed and it was concluded that thermal stress is the main reason for the failure of hot forging die. Based on this conclusion, the whole hot forging die was divided into the substrate part and the heat-resistant part according to the thermal stress distribution. Moreover, the heat-resistant part was further subdivided into more zones and the material of each zone was reasonably selected to ensure that the hot forging die can work in an elastic state. When compared with the existing techniques, this design can greatly increase the service life because the use of multi-materials can alleviate the thermal stress in hot forging die.

Tempering stability of Fe–Cr–Mo–W–V hot forging die steels

The tempering stability of three Fe–Cr–Mo–W–V hot forging die steels(DM, H21, and H13) was investigated through hardness measurements and transmission electron microscopy(TEM) observations. Both dilatometer tests and TEM observations revealed that DM steel has a higher tempering stability than H21 and H13 steels because of its substantial amount of M_2C(M represents metallic element) carbide precipitations. The activation energies of the M_2C carbide precipitation processes in DM, H21, and H13 steels are 236.4, 212.0, and 228.9 kJ/mol, respectively. Furthermore, the results indicated that vanadium atoms both increase the activation energy and affect the evolution of M_2C carbides, resulting in gradual dissolution rather than over-aging during tempering.

Effect of Rare Earth Composite Modification on Microstructure and Properties of a New Cast Hot-Work Die Steel

The effects of RE modification on structure and the properties of a new cast hot work die (CHD) steel were investigated. The grains of the CHD steel are refined by RE modification. With the increase of RE addition, both grain size and inclusion amount are reduced. Appropriate amount of RE results in decrease in inclusion amount and formation of spheroidal inclusions uniformly-distributed in steel, so that the morphology and distribution of inclusions are improved. RE composite modification favors the formation of bainite, austenite and fine lath martensite with dense dislocation. When the residual RE content reaches 0.02%, no obvious changes in strength and hardness are found, while fracture toughness and threshold of fatigue crack growth are increased. The impact toughness, elongation and reduction of cross sectional area are increased by a factor of two, and thermal fatigue resistance is also improved.

Calculation and Analysis of Valence Electron Structure of Mo_2C and V_4C_3 in Hot Working Die Steel

Taking the hot working die steel （HWDS） 4Cr3Mo2NbVNi as an example, the phase electron structures （PES） and the biphase interface electron structures （BIES） of Mo2C and V4 C3 , which are two kinds of important carbides precipitated during tempering in steel were calculated, on the basis of the empirical electron theory of solids and molecules and the improved TFD theory. The influence of Mo2 C and V4 C3 on the mechanical properties of HWDS has been analyzed at electron structure level, and the fundamental reason that the characteristic of the PES and the BIES of carbides decides the behavior of them has been revealed.

Ni60-SiC Coating Prepared by Plasma Spraying, Plasma Re-melting and Plasma Spray Welding on Surface of Hot Forging Die

In order to produce the hear-resistant inner layer of hot-forging die, plasma spraying and plasma re-melting and plasma spray welding were adopted. Substrate material was W6Mo5Cr4V2, including 10%, 20%, 30% SiC ceramic powder used as coating material to obtain different Ni-based SiC alloys coating. Micro-structure and micro-hardness analysis of the coating layer were followed, as well as thermophysical properties for the coating layer were measured. The experimental results show that the coating prepared with 70% Ni60, 30% SiC powder has best properties with plasma spray welding, in which the micro-hardness can achieve 1100 HV, meanwhile can improve the thermal property of hot-forging die dramatically.

Theoretical modeling of cutting temperature in high-speed end milling process for die/mold machining

A parametric model of cutting temperature generated in end milling process is developed according to the thermal mechanism of end milling as an intermittent operation, which periodically repeats the cycle of heating under cutting and cooling under non-cutting. It shows that cutting speed and the tool-workpiece engagement condition are determinative for tool temperature in the operation. The suggested model was investigated by tests of AlTiN coated endmill machining hardened die steel JIS SKD61, where cutting temperature on the flank face of tool was measured with an optical fiber type radiation thermometer. Experimental results show that the tendency of cutting temperature to increase with cutting speed and engagement angle is intensified with the progressing tool wear.

Influence of Different Surface Treatments of H13 Hot Work Die Steel on Its Thermal Fatigue Behaviors

Thermal fatigue checking is the general failure of hot work die steels, which is relative with the structures and properties of the steels and the stress alternated during the employment. The Uddeholm test method on thermal fatigue is used to compare the behaviors of different samples, which are treated with plasma nitriding、plasma sulfur carbon nitriding、boronizing or not treated. The results show that the nitriding improves the thermal fatigue property of the tool steel, while the plasma sulfur carbon nitriding and the boronizing impair the property. The mechanisms are induced as follows. By increasing the hardness and changing the stress distribution in the surface layer, surface treatment can decrease the plastic deformation and the tensile stress during the cycling. Therefore, the generation and growth of the cracks are restrained. On the other hand, as results of surface treating, in the surface layer the toughness declines and the expanding coefficient ascendes; the latter change caused the strengthening of the tensile and compressive stress during the cycling. Thus the resistance to thermal fatigue is weakened. Whether or not the surface treatment is favor to thermal fatigue of tool steels relies on which factor is dominant.

Mold Wear During Die Forging Based on Variance Analysis and Prediction of Die Life

A process parameter optimization method for mold wear during die forging process is proposed and a mold life prediction method based on polynomial fitting is presented,by combining the variance analysis method in the orthogonal test with the finite element simulation test in the forging process.The process parameters with the greatest influence on the mold wear during the die forging process and the optimal solution of the process parameters to minimize the wear depth of the mold are derived.The hot die forging process is taken as an example,and a mold wear correction model for hot forging processes is derived based on the Archard wear model.Finite element simulation analysis of die wear process in hot die forging based on deform software is performed to study the relationship between the wear depth of the mold working surface and the die forging process parameters during hot forging process.The optimized process parameters suitable for hot forging are derived by orthogonal experimental design and analysis of variance.The average wear amount of the mold during the die forging process is derived by calculating the wear depth of a plurality of key nodes on the mold surface.Mold life for the entire production process is predicted based on average mold wear depth and polynomial fitting.

CYCLIC SOFTENING IN HOT-WORKING DIE STEELS DURING LOW-CYCLE FATIGUE

The characteristics and microstructural changes of cyclic softening in hot-working die steels 5CrNiMo and 5Cr2NiMoVSi were studied under strain controlled low-cycle fatigue.The re- sults show that the cyclic softening is featured in both steels hardened in different conditions under the strain controlled amplitude range of Δε_t/2=0.6-1.8×10^(-2).The softening effect mainly occurs in some initial cycles and the stress amplitude varies slightly in the sequential cycles,i.e.the softening effect is minified.No obvious stress saturation phenomenon was ob- served during the whole cyclic deformation.The TEM analysis shows that the cyclic softening is related to heterogenity of plastic deformation.The softening of the tested steels is caused by the formation of the dislocation cell structure with low density and low internal stress,and by the fragmentation and redissolution of fine carbides into matrix.

Carbide Coating Preparation of Hot Forging Die by Plasma Processing

To meet the performance requirements of hot forging die heat resistant layer, the Ni60-SiC coating, Ni60-Cr3C2 coating, and Ni60-WC coating were prepared using W6Mo5Cr4V2 as substrate material with 30%SiC, 10%Cr3C2, 30%WC powder by means of plasma spraying and plasma spray re-melting and plasma spray welding, respectively. Microstructure of each carbide coating was analyzed, micro-hardness was tested, and mainly thermal parameters of coating were detected. The experimental results show that using plasma spray welding, the performance of 70%Ni60/30%SiC powder is the best, and its micro-hardness can achieved 1100HV, showing good thermal-physical property.

APPLICATION OF RARE EARTH IN SURFACE HEAT TREATMENT OF HOT-WORKING DIE STEELS

This paper studies a compound treatment. i. e. liquid S , N,C co-diffusing with rare earth (RE) and then oxidization , for hot-working die steels , and the effect of RE on thermal fatigue behavior of the diffused layer. XRD and SEM energy spectrum prove that trace RE element actually penetrates into the surface layer of steels. The result shows that RE can reduce the gradient of change of hardness in diffused layer, improve the morphology and distribution of compounds , and reduce the degree of surface alligator crack for thermal fatigue. The behavior of thermal fatigue of hot-working die steels is raised by 70% or so after the application of RE. The effect of RE is analysed according to the theory.

Effect of Alloying Elements on Thermal Wear of Cast Hot-Forging Die Steels

The effect of main alloying elements on thermal wear of cast hot-forging die steels was studied. The wear mechanism was discussed. The results show that alloying elements have significant influences on the thermal wear of cast hot-forging die steels. The wear rates decrease with an increase in chromium content from 3% to 4% and molybdenum content from 2% to 3%, respectively. With further increase of chromium and molybdenum contents, chromium slightly reduces the wear resistance and molybdenum severely deteriorates the wear resistance with high wear rate. Lower vanadium/carbon ratio （1.5-2.5） leads to a lower wear resistance with higher wear rate. With an increase in vanadium/carbon ratio, the wear resistance of the cast steel substantially increases. When vanadium/carbon ratio is 3, the wear rate reaches the lowest value. The predominant mechanism of thermal wear of cast hot-forging die steels are oxidation wear and fatigue delamination. The Fe2O3 and Fe3O4 or lumps of brittle wear debris are formed on the wear surface.

Research on Thermal Wear of Cast Hot Forging Die Steel Modified by Rare Earths

Thermal wear of cast hot-forging die steel modified by rare earths（RE） was studied and compared with commercially used die steels. The function of RE and the mechanism of thermal wear of cast steel modified by RE were discussed. The results showed that with increasing content of RE, the wear rate of cast steel reduced at first and then increased. By adding 0.05% （mass fraction） RE, the cast hot-forging die steel with optimum thermal wear resistance was obtained, which was better than that of H13 and 3Cr2WSV. The large amount of coarse inclusions, （RE）2O2S, resulted from excessive RE, which obviously deteriorated thermal wear resistance. The mechanism of thermal wear of the modified cast die steel is oxidation wear and oxide fatigue delamination. The wear debris are lumps of Fe2O3 and Fe3O4.

基于Moldex3D的油漆桶桶盖注塑成型过程分析

利用模流分析软件Moldex3D模拟油漆桶桶盖注塑成型过程,研究桶盖模具使用阀式热流道与开式热流道两种不同浇注方案的成型差异,并结合仿真结果设计热流道。通过设计Taguchi DOE实验的因素与水平,优化桶盖产品的注塑工艺参数。结果表明:设定工艺参数为熔体温度250℃,保压时间2 s,冷却时间18 s时,产品没有短射、包封等外观质量问题;优化后的注塑工艺参数有效降低了产品的冷却时间。

Low-cycle fatigue behavior of permanent mold cast and die-cast Al-Si-Cu-Mg alloys

Fatigue failure is one of the main failure forms of Al-Si-Cu-Mg aluminum alloys. To feature their mechanical aspect of fatigue behavior, the low-cycle fatigue behavior of permanent mold cast and die-cast AI-Si- Cu-Mg alloys at room temperature was investigated. The experimental results show that both permanent mold cast and die-cast AI-Si-Cu-Mg alloys mainly exhibit cyclic strain hardening. At the same total strain amplitude, the diecast AI-Si-Cu-Mg alloy shows higher cyclic deformation resistance and longer fatigue life than does the permanent mold cast AI-Si-Cu-Mg alloy. The relationship between both elastic and plastic strain amplitudes with reversals to failure shows a monotonic linear behavior, and can be described by the Basquin and Coffin-Manson equations, respectively.

Mold Filling and Prevention of Gas Entrapment in High-pressure Die-casting

This paper presents some results of direct observation of mold filling in a specially designed die-casting by X-ray diffraction, including comparison with numerical simulation. Based on such work the authors discuss how to prevent gas entrapment and propose new methods.