H. Lindow, Dipl.

Ing, Senior Adviser

Subjects S bjects On Die Fail es In Die Casting Failures

Subjects On Die Failure b l

Die material Die design Die making process Heat treatment Surface treatment Process parameters P t

H. Lindow

Selection Of Die Material for HPDC

Cast Metal Temperature Die Size eS e Chemical composition Steel production parameters Production Series Shape of the contour

H. Lindow

Casting t C ti temperatures of various alloys t f i ll

Die Cavity Wall Temperature Dependent On Cast Metal and Preheating Temperature

H. Lindow

Die Cavity Wall Temperature

Influence on: Cavity wall strength Thermal stress

H. Lindow

Cycles Until Visible Cracks Of 0,15mm Dependent On y , p Surface Temperature

No cracks at 300 C as in Zn-Die Casting C Zn Die Crack Depth (mm) D ( 7.000 cycles 2.500 cycles
0,15
550 620

800 cycles 400 Cycles

670

H13, SKD61, 1.2344 690 HRC 44 to 47

2000

4000

6000

8000

Number of Cycles
7

H. Lindow

Crack Propagation Until 10 7 m Dependent 10,7 On Surface Temperature

Crack Depth (mm) k h

1.000.000 200,000 20.000 3.000 H13, SKD61, 1.2344 HRC 44 to 47

Cycles x 1.000
8

H. Lindow

Die T Di Temperature t

Influence on: Die cavity wall temperature thermal stress

H. Lindow

Influence Of Temperature / T Stress / Strength

Stre N/m ess mm / St trength N/ mm

1500 N/mm ~HRC 45

Temperature / Temperature difference C C

10

H. Lindow

DIE SIZE

Influence on: Toughness Heat treatment Hardenability of the die material

11

H. Lindow

Grouping of standard materials according to Cross section

Small dies Medium dies Big dies < 70 mm and their corresponding flat sizes (42x250; 45x140; 50x100; 60x75 m) 70 140 mm and their corresponding flat sizes (90x300; 100x250; 120x150 mm) > 140 mm and their corresponding flat sizes (140x230; 180x300; 200x250; 230x280)

Note The toughness shown at the brochures diagram demonstrates the toughness of the steel only without considering the influence coming from th h t t f the heat treatment. D t t Due t th small size of th t t to the ll i f the test-specimen i (7 x 10 x 55 mm) the effect of the heat treatment is optimal. But with the increase of the cross section of a die the slower the cooling speed becomes from hardening temperature at a specific cooling medium medium.
12

H. Lindow

In order to have sufficient toughness the structure should at least consist of 20% Martensite and 80% Bainite and as less as possible carbide precipitation. With the increase of f Bainite especially coarse Bainite and with the increase of carbide precipitation the toughness is decreasing. If the die maker is not sure about the heat treatment and if the die is of a big size always it is advisable to choose a material which will more or less guarantee the above mentioned structure independent from the chosen heat treatment process. In such a case choose a die material with a better hardenability than that of the ordinary standard material as H13; SKD61; 2344 Such materials are:

DIEVAR VIDAR SUPERIOR

13

H. Lindow

Structure at ~ 6.4 (640s) for a Size Range of 380 to 45 mm (80%B/20%M) dependent on the Heat Transfer for 8407 (H13; SKD61; 1.2344)

~ 6.4

14

Name, Company, Date

 52 (5200s) for DIEVAR ( > 1000-350 mm) 1000 350 Gives A Similar Structure as ~ 6.4 (640s) ( ( 380-45) for H13 )

~ 6,4

~ 52

15

H. Lindow

Reachable Diameter For H13 Dependent On Cooling Medium and a fixed Q-Velocity of 28C/minute ( ~ 6.4 (640s)) at Core Area
e.g 80% B + 20%M for 8407 at core area

16

H. Lindow

in mm

Toughness Dependent On Hardenability h d d bl

HRc 45 21 J

HRc 45 6J

17

Name, Company, Date

Toughness Comparison At Surface Of Large Size Blocks Bl k At Various Quenching Rates V i Q hi R t (Block Sizes 300 x 500 x 700 mm)

HRC 45

18

H.Lindow

Reachable for 80% Bainite and 20 % Martensite in the core area dependent on Cooling Medi m and co e a ea Medium Various Types of Steels
DIEVAR 8407 2M 8407-2M in mm QRO90S

19

H. Lindow

Hardenability

80 0

100

60

Martensite %

DIEVAR VIDAR SUPERIOR ORVAR SUPREME QRO90SUPREME

20

50

100

200

300

400

Diameter in mm Percentage of Martensite / Bainite in the centre at various diameters After Quenching in Oil to 200 C
20

Name, Company, Date

80

40 60 e Bainite %

40

20 0

Chemical composition p

Influence on
creeping strength i h ductility hot strength toughness thermal stress hardenability corrosion resistance
21

Crack initiation

Crack propagation Crack initiation + Crack propagation Toughness related to heat treatment

H. Lindow

22

H. Lindow

D Ductility

84 407 2M 8407Su

Ductility D tilit

DIEVAR R

HRC 45 / 46

VIDAR Super S

QRO90Su u

Product Of Creeping Strength And Ductility (Resistance To Crack Initiation)

Cree eping strength x Duc s ctility

200

10 00

X 1000

HRC 45

23

H. Lindow

HRC 50 5

Creeping test 1%, 550 C 500 MPa, 1000 h % C,

24

H Hot-Yield Strengt in N / mm m
H. Lindow

8407

Hot-Yield Strength At 600 C

HRC 45 / 46
DIEVAR R VIDAR Super S QRO90Su u

Comparison Of Toughness At RT In ST p g
Size of specimen 7 x 10 x 55 mm (Charpy V)

Toug ghness. J

DIEV VAR, HRC 52 C

ORV VAR Su

8407 2M 7

VIDA Super AR r.

DIEV VAR

HRC 45 / 46
25

HRC 52

Name, Company, Date

HRC 45 / 46

QRO O90Su

Toughness Dependent On Carbide Precipitation

Cooling time from AT in Seconds e T

VIDAR Superio R or

7000

10 00

Carbide Precipitation
26

H. Lindow H.Lindow

D DIEVAR

Q QRO90Su u

8407

Product Of Hot-Yield Strength (600) C And Toughness g ( ) g (Resistance to crack propagation)

Hot-Yield Stre ength X Toughn ness/ 10 0 (NJ/mm m)

8407 2M

HRC 45/46 /
27

HRC 52

H. Lindow

D DIEVAR, HRC52 H

O ORVAR Su u

V VIDAR Su uper

Q QRO90Su

D DIEVAR

Temper Back Resistance At 600C - 10 Hours

Hardn ness, HR RC

Q QRO90Su

HRC 45 / 46

28

H. Lindow

D DIEVAR

V VIDAR Su uper

8 8407

Relation Heat Conductivity / Thermal Expansion

255 250 V VIDAR Superio S or 245 8407 240 235 230 225 220 Kategorie 1

29

H. Lindow

D DIEVAR R

QRO90 0S

30

(Produc Hot Strength, ct Toughness ) x 0,1 Therm s 1/ mal C Conductivity, - Expansio E on

Relation Hot Yield Strength, Toughness To Thermal Strength Conductivity, - Expansion

H. Lindow

8407Su upreme e DIEVAR R

VIDAR Superio R or

QRO90Su

100
8407 2M 2

200

300

400

500

600

Corrosion R i t C i Resistance I A Al-Melt In An Al M lt

Reciprocal value x 1000

Al (A356) Si 7% Mg 0 3%) 7%-Mg 0,3%) 720 C 5 h Melt t ti 4,4 / i M lt rotation 4 4 m/min Specimen size 20 x 95 (100) mm

31

H. Lindow

Production parameters

Influence on:
D tilit Ductility Toughness Residual stresses

32

H. Lindow

Process Development Regarding Reduction Of p g g Total Oxygen Content

Oxyge conten in ppm en nt m

Year
33

H. Lindow

Improvement Due To Cleaner Materials

Old ESR-process New ESR-process Advantages Re-melting under a protective atmosphere t ti t h Process with a static mould Result More cleaner material Improved solidification Better isotropic material Smaller and less primary carbides

34

H. Lindow

Comparison of a standard and a supreme steel p p

35

H. Lindow

Homogenizing
Degre of micro-segregation ee n Micro-segregation also after ESR-and VAR-process

Cast condition

Longer time and or 9 h at high or longer time at lower temperature temperature higher temperature

9 hours at a high

Residual stress in between micro-segregation may go up to 150 N / mm

36

H. Lindow

Homogenizing heat treatment

Standard

Homogenizing is a diffusion annealing process carried out at a very high temperature and a long soaking time. The purpose is to reduce p p microsegregations and size of primary carbides which will result in improvement of: ; ductility and ; touhness in all directions

37

H. Lindow

Homogenized

IMPACT STRENGTH VERSUS VARIOUS PROCESSES, HRC 43/45; TL

Surface Centre DIEVAR

400 300 200 100

Standard Material H13;
38

ESR

H. Lindow

ESR under protective gas

VAR

ESR+H

Die St l S l ti Di Steel Selection

Product of cre eep-/ho streng and ot gth Ductility- toughness QRO90S Impax Orvar 2M Vidar Superior Unimax

Cu

DIEVAR VIDAR S Superior i ORVAR S

Al Mg M
Unimax Vidar Superior, Dievar Elmax

Zn

Erosion / Corrosion

Thermal Fatigue (Heat Checking)

39

H. Lindow

DESIGN

Influence on: Erosion Soldering Corrosion Thermal fatigue cracks Heat cracks Chipping Gross cracks Releasing marks R l i k Temper back at cavity wall

40

H. Lindow

Un-suitable Parameters Due To Wrong Design

Gate area Make the most suitable gate design Avoid an un-suitable relation of melt volume to gate area Avoid an un-suitable relation gate area to runner Avoid an gate opening too small or too big Look into relation of gate area filling time area, time, melt velocity, plunger diameter and its velocity Location of the gate area Observe relation gate opening to gate width Put right relation of gate section to runner section

41

H. Lindow

Basic Rules For Gate Location

Try to avoid premature cavity erosion Avoid creation of hot spots Choose most direct path what means fill away from gate first p y g Avoid impingement on cores Direct metal flow in line with long ribs, not across them Gate should be placed opposite the longest unhindered metal flow path Use only one gate for one casting. Multiple gates may cause more trouble Avoid too thin a gate if possible Do not place the gate near very thin sections with fine details Avoid impingement on convex sections

42

H. Lindow

43

H. Lindow

First choose filling time c e e

Filling Ti Filli Time D Dependent O Solidifying Temperature d t On S lidif i T t Of The Al-Alloy

Al 99,9 % DIN 226 230 231 239

44

658 C C GB

0 C C USA-ASTM A380,0 A413 ASIA-JIS

Furnace temp. EURO NORM

G-AlSi9Cu3 LM 24 G-AlSi12 LM 6 G-AlSi12(Cu) LM 20 G-AlSi10Mg LM 9

ADC10 (12) EN Al 46000 AC3A EN AL44300 ADC1 EN Al 47100 AC4A EN Al 43000

H. Lindow

Filling Time Dependent On Part - Wall Thickness

45

H. Lindow

Filling Times For Various Alloys And Die Preheating Temperatures

Alloy AlSi12 Mg-Alloy Brass Filling Time ms 4 - 161 12 - 17 60 - 90 8 - 60 50 60 Sm mm 16 1 6 1,5 15-4 2,16 3,43 Die Temp C 204 260 280 280 350 350 350

Die preheating temperatures Pb, Sn Al 120 C 180 260 C Zn Mg 150 200 C 250 330 C

Cu-Alloys 300 - 350 C

46

H. Lindow

Filling Times For Al Alloys Al-Alloys

47

H. Lindow

Filling Times For MG

Average wall thickness mm 1 2 3 4 5 6

Recommended filling times ms 12 25 40 48 55 60 to to to to to to 17 48 60 70 80 90

48

H. Lindow

General Formula For Melt Velocity At The Gate 4

Wa = Cw

Sm

Cw Zn 46; Al 51 Mg 57, 51, 57

Wa Zn 30 to 50 m / s;

Al 20 to 60 m / s;

Mg 40 to 90 m / s; Cu 20 t0 50 m / s

49

H. Lindow

Temperature Increase At Cavity Wall p y Dependent On Melt Velocity At The Gate

Melt velocity at gate t

50

H. Lindow

Temperature increase

Melt Velocity At Gate

Gate Velocity a) Hi h velocity for parts with thin ) High l i f i h hi wall b) Al 20 to 60 m / s min. 18 m / s e.g. 33 m / s for Sm = 6 mm Vacuum 15 to 30 m / s c) Mg 40 to 90 m / s min. 27 m / s e.g. e g 36 m / s for Sm = 6 mm d) Zn 30 to 50 m / s min. 12 m / s e.g. e g 29 m / s for Sm = 6 mm e) Cu 20 to 50 m / s Too high a velocity may damage the die by erosion, soldering, corrosion and also fatigue
51

H. Lindow

Formula For Gate Area

Sa = V

tf x wa

52

H. Lindow

Gate Area For Parts More Than 150 g

b x d = Agk x Wp / Wa ( (mm) )
b = width of gate d = gate opening Agk = area plunger Wp = velocity plunger Wa = velocity melt at gate l it lt t t

53

H. Lindow

Velocity Piston
Al die casting below 3 m s Mg die casting b l below 4 5 m / s 4,5

Wgk = V / Agk x tf k k
Wgk = velocity piston; V = Volume melt after gate; Agk = area plunger; tf = filling time g
54

H. Lindow

Guiding Table g e

1 2 6 4 5

55

Name, Company, Date

Relation Gate Area to Volume Dependent On p Average Wall Thickness, Gate Opening, Alloy
Average wall thickness (mm) 1,5 1,75 1 75 2,0 2,5 3,0 3,5 4,0 4,5 , 5,0 5,5 6,0
56

Gate opening (mm) 0,9 0,95 0 95 1,0 1,1 1,2 1,3 1,4 1,5 , 1,7 1,8 2,0

Relation Sa / V (mm / cm) Type of Alloy Al Mg Cu C Zn Z 1,48 1,14 1 14 0,94 0,69 0,54 0,44 0,37 0,32 , 0,30 0,27 0,25 1,66 1,23 1 23 1,04 0,78 0,60 0,49 0,41 0,36 , 0,33 0,29 0,25 , 3,57 2,86 2 86 2,41 1,75 1,41 1 41 1,15 0,98 0,86 0,79 0,71 0,65 , 1,77 1,39 1 39 1,16 0,86 0,70 0 70 0,58 0,49 0,43 0,40 0,35 0,33 ,

H. Lindow

General Advise F G t Opening G l Ad i For Gate O i

Finding of gate opening (general rules) Al die casting AlSi >>Si AlSiCu Mg die casting Zn die casting ZnAl4 (Zamak 3) ZnAl4Cu1 (Zamak 5) Cu die casting 1,0 to 2,5 mm min. 1 mm > 1 mm min. 1,2 mm 0,6 to 2 mm 0,35 to 1,2 mm 0,35 to 0,8 mm 0,5 to 1,2 mm 1,5 to 3,0 mm

57

H. Lindow

Formula For Gate Opening In Al Die Casting l l

d = 0,52 + 0,28 x S , , d = 0 6 + 0 2 x Sm 0,6 0,2

(for 1 < Sm < 4,5 mm)

d = Sm / 3
(for 4,5 < Sm < 6 mm)

d = gate opening; S = part wall thickness

58

H. Lindow

59

H. Lindow

20-35

60

H. Lindow

61

H. Lindow

SA part

L=1,5xB , B R 35 B R 0,5B

AK0=2 SA

Same distance R

AK1=2AKo

1/3L L 2/3L

AK0

Same distance

AK2=4AK0

AK=4 AK0 = AK2 AK0=2 SA 2

62

H. Lindow

R not bi t big Else fills at first

63

H. Lindow

1/2 D

2 2/3 D D

64

H. Lindow

65

H. Lindow

Cavity wall temperature control by internal cooling l l

Influence on: Thermal fatigue cracks Thermal stress cracks Thermal expansion Releasing marks Soldering Erosion Corrosion

66

H. Lindow

Surface Temperature
Surface temperature dependents on a) Metal temperature and its heat capacity it s Zn 450 C Mg 670 C (low heat capacity) AlSi9Cu3 680 720 C C AlSi12(Cu) 680 720 C (high heat Capacity) Ms 970 C ) y g , b) Cavity contour and die design-wall thickness, cores c) Die preheating Temperature d) Frequency of cycles e) Position of joint contour of both die parts f) Condition of die filling as filling time, melt velocity, plunger velocity; metal flow in the cavity g) Die internal cooling heating system; lubrication; h) Cast system (gate, runner, bush) its design and location; number of overflows

Good heat transfer Bad heat transfer

Bad heat transfer

Note: A surface temperature higher or lower of 20 C may decrease Date increase the die life by 30 to 50 % Name, Company, or
67

A simulation program will b helpful for finding i l ti ill be h l f l f fi di where the cooling channels should be placed

68

H. Lindow

Temperature Profile Cavity Wall

630C

Temperature profile Taken with an Infrared Camera T k ith I f dC

69

Simulation curves for Heating and cooling

H. Lindow

Hot Spots

Hot spots Hot spots causing: Product p p g porosity; Soldering; Early heat checking; y; g; y g; Corrosion / Erosion
70

H. Lindow

Temperature Flow In Vertical Direction p

71

H. Lindow

a) b) c) d) ) e)
72

Better to have more small cooling channels than a few big ones When using water, 9 to 12 mm; when using oil, 12 to 15 mm Distance cooling channel to cavity in general 25 mm, gate area 28 mm Cooling channel depending on wall thickness of the part Distance of cooling channels, max 3 x g ,

H. Lindow

Internal C li I t l Cooling Of N Narrow Walls W ll

In I narrow areas use C b Cu-bar connected to a cooling channel Diameter of a Cu-bar in a cylindrical area

Use Cu-paste for heat transfer from Cu-bar to cylindrical wall (clearance 0.05 0.1 mm, Ra<1 m)
73

H. Lindow

Cooling With Heat Conducting Tubes

74

H. Lindow

75

H. Lindow

Design Of Ejectors
They should not be put at the gate area!

76

H. Lindow

Design Of Venting g g
Put venting as much as possible but as less as necessary

77

H. Lindow

78

H. Lindow

TRUST IS SOMETHING YOU EARN EVERY DAY. EARN, DAY