Method for improving the service life of die casting mold
Die-casting molds are expensive due to their long production cycles, high manufacturing precision, and significant investment. Therefore, maximizing their service life is essential to reduce waste and save costs. However, factors such as material defects, improper processing, and incorrect usage can lead to premature failure, resulting in costly replacements.
Common failure modes include corner cracks, hot cracking, wear, erosion, and structural splitting. These issues often stem from material flaws, machining errors, improper heat treatment, or inadequate maintenance.
First, material defects
The working conditions of die-casting molds are extremely harsh. For example, aluminum die-casting molds must withstand temperatures up to 720°C. Without proper preheating, the mold surface experiences extreme thermal stress, leading to micro-cracks after repeated cycles. This makes it crucial to select materials with excellent thermal fatigue resistance, toughness, and stability. H13 (4Cr5MoV1Si) is widely used due to its superior properties, while 3Cr2W8V is gradually being phased out due to poor thermal conductivity and higher risk of cracking.
Before production, rigorous material inspections are necessary. Methods include macroscopic corrosion tests, metallographic analysis, and ultrasonic testing to detect porosity, inclusions, and internal defects. Ensuring high-quality raw materials is the first step toward extending mold life.
Second, processing, use, and maintenance
Proper design and manufacturing play a key role in mold longevity. Injection speed, for instance, should be optimized—too fast can cause wear, too slow may result in incomplete filling. For aluminum, the ideal injection speed is around 18 m/s, while the maximum should not exceed 53 m/s.
During machining, attention must be paid to cooling channels and surface finish. EDM (Electrical Discharge Machining) can create a hardened layer on the mold surface, which may lead to cracking if not removed. Grinding or stress relief treatments are recommended to minimize this risk.
Finally, during operation, controlling the mold preheating temperature and reducing casting temperatures can significantly improve performance. Increasing the preheating temperature from 100–130°C to 180–200°C can extend the mold’s life considerably. Regular maintenance and proper handling are also vital for long-term durability.
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