Tj-Ningbo.materialDesignUddLayout [Automatisch Gespeichert]

8/2/2019 Tj-Ningbo.materialDesignUddLayout [Automatisch Gespeichert]

1/79

H. Lindow, Dipl.Ing, Senior Adviser

u ec s n e a ures n e as ng


2/79

Subjects On Die Failure

Die design

Die making process

Heat treatmentSurface treatment

rocess parame ers

H. Lindow2


3/79

Selection Of Die Material for HPDC

Cast Metal Temperature Die Size

Chemical composition Steel production parameters Production Series Shape of the contour

H. Lindow3


4/79

as ng empera ures o var ous a oys

4


5/79

Cast Metal and Preheating Temperature

H. Lindow5


6/79

Die Cavity Wall Temperature

n uence on:

Cavity wall strength

H. Lindow6


7/79

C cles Until Visible Cracks Of 0,15mm De endent On

Surface Temperature

-

(mm)

7.000 cycles

0,15 550 620

Depth

800 cycles

2.500 cycles

670 690

Crack

400 Cycles

H13, SKD61, 1.2344HRC 44 to 47

0 2000 4000 6000 8000

H. Lindow7

Number of Cycles


8/79

,On Surface Temperature

(mm)

1.000.000

Dept

20.000

200,000 H13, SKD61, 1.2344HRC 44 to 47

Crac

3.000

H. Lindow8 Cycles x 1.000


9/79

e empera ure

Influence on:

Die cavity wall temperature thermal stress

H. Lindow9


10/79

Influence Of Temperature / T Stress / Strength

1500 N/mm ~HRC 45

N/

mm

1500 N/mm ~HRC 45

N/

mm

rength

rength

m/S

m/S

s

sN/

s

sN/

Str

Str

H. Lindow10


11/79

DIE SIZE

Influence on:

Heat treatment

material

H. Lindow11


12/79

Cross section

Small dies < 70 mm and their corresponding flat sizes

(42x250; 45x140; 50x100; 60x75 m)

Medium dies 70 140 mm and their corresponding flat sizes(90x300; 100x250; 120x150 mm)

Big dies > 140 mm and their corresponding flat sizes(140x230; 180x300; 200x250; 230x280)

NoteThe toughness shown at the brochures diagram demonstrates the

toughness of the steel only without considering the influence comingrom e ea rea men . ue o e sma s ze o e es -spec men(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

H. Lindow12

.


13/79

In order to have sufficient toughness the structure shouldat least consist of 20% Martensite and 80% Bainite andas less as possible carbide precipitation. With the increase ofBainite 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 dieis of a big size always it is advisable to choose a material which

independent from the chosen heat treatment process.In such a case choose a die material with a better hardenability

Such materials are:

VIDAR SUPERIOR

H. Lindow13


14/79

Structure at ~ 6.4 640s for a Size Ran e of

380 to 45 mm (80%B/20%M) dependent on theHeat Transfer for 8407 (H13; SKD61; 1.2344)

~ 6.4

Name, Company, Date14


15/79

-Gives A Similar Structure as ~ 6.4 (640s)

( 380-45) for H13

~ 52 ~ 6,4

H. Lindow15


16/79

Reachable Diameter For H13 Dependent On Cooling

Medium and a fixed Q-Velocity of28C/minute( ~ 6.4 (640s)) at Core Area

e.g 80% B + 20%M for 8407 at core area

mm

i

n

H. Lindow16


17/79

Toughness Dependent On Hardenability

HRc 45

21 J

HRc 45

6 J



18/79

Toughness Comparison At Surface Of Large Size

oc s t ar ous uenc ng ates(Block Sizes 300 x 500 x 700 mm)

HRC 45

H.Lindow18


19/79

Reachable for 80% Bainite and 20 % Martensite in

e core area epen en on oo ng e um anVarious Types of Steels

DIEVAR

8407-2M

QRO90S

mm

in

H. Lindow19


20/79

Hardenability

100

60

80

20

40

%

VIDAR SUPERIOR

ORVAR SUPREMEartensite

40 60Bain

it

M20

80

50 100 200 300 400

Diameter in mm

Percentage of Martensite / Bainite in the centre at various diameters



21/79

Chemical com osition

Influence on

creeping strengt

ductility Crack initiation

hot strength toughness

Crack propagation

thermal stress Crack initiation Crack propagation+

corrosion resistance

H. Lindow21


22/79

uct ty

uctilit

y

072M

uper

84

D

IEVAR

V

IDAR

8

407Su

Q

RO90S

H. Lindow22


23/79

(Resistance To Crack Initiation)

2

00

Creeping test 0tility

0

1%, 550 C, 500 MPa, 1000 h

HRC

hxDu

1

X

100

0

trengt

HRC 45

0

eping

Cre

H. Lindow23


24/79

inN/m

Strengt

Super

u

o

t-Yield

8

407

D

IEVAR

VIDAR

QRO90S

HRC 45 / 46

H. Lindow24


25/79

Comparison Of Toughness At RT In ST

Size of specimen 7 x 10 x 55 mm (Charpy V)

J

hness.

52

.

Tou

2M

A

R

A

R,

HR

RSupe

90Su

ARSu

840

DIE

DIE

VID

QRO

OR


HRC 45 / 46HRC

45 / 46

HRC

52


26/79

ou ness epen en n ar e rec p a on

nd

s

inSeco

r

from

A

7000

Supe

ri

lingtim

0

8407

IEVAR

VIDA

QRO90S

Coo

1

H. Lindow26

H.Lindow


27/79

Product Of Hot-Yield Stren th 600 C And Tou hness

(Resistance to crack propagation)

ess/1

Tough

)

ngth

X

(NJ/m

072M

per

RC52

u

ie

ldStr 8

4

I

EVAR

I

DARS

IEVAR,

R

O90Su

R

VARS

Hot-Y

HRC 45 46

HRC

52

H. Lindow27


28/79

Temper Back Resistance At 600C - 10 Hours

RC

ness,

H

per

Hard

407

I

EVAR

I

DARS

R

O90Su

HRC 45 / 46

H. Lindow28


29/79

Relation Heat Conductivity / ThermalExpansion

255

245

250

r

235

240

8407

uperi

S

225

230

I

DAR

IEVA

Q

RO9

220

Kategorie 1

H. Lindow29


30/79

,Conductivity, - Expansion

600, a

l

n

400

500

Mtrength

/Ther

xpansi

r

3008407

RtHot

S

)x0,

vity,-

Sup

rem

Supe

ri

100DIEVA

(Produ

ughnes

o

nducti

QRO90

8

407S

VIDAR

0To

H. Lindow30


31/79

orros on es s ance n n - e

Al (A356)

1

000

- ,

720 C 5 h

value

e ro a on , m m n

Specimen sizeprocal

20 x 95 (100) mm

Reci

H. Lindow31


32/79

ro uc on parame ers

Influence on:

uc y

Toughness Residual stresses

H. Lindow32


33/79

Process Develo ment Re ardin Reduction Of

Total Oxygen Content

tin

pp

nconte

Oxyg

Year

H. Lindow33


34/79

Improvement Due To Cleaner Materials

Old ESR-process New ESR-process

Advantages

Re-melting under apro ec ve a mosp ere

Process with a staticmould

ResultMore cleaner materialBetter isotropic materialSmaller and less

rimar carbides

H. Lindow34


35/79

Comparison of a standard and a supreme steel

H. Lindow35


36/79

Micro-segregation also after ESR-and VAR-process

re

gatio

re

gatio

cro-seg

cro-seg

eofmi

eofmi

9 hours at a hightemperature

Cast condition Longer time and orhigher temperatureD

egr

Degr

9 h at high or longer time at lower temperature

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

H. Lindow36


37/79

Homogenizing is adiffusion annealing process

Standard

temperature and a long soakingtime.The ur ose is to reducemicrosegregations and sizeof primary carbides whichwill result in improvement of:

; ductility and

; touhness in all directions

H. Lindow37 Homogenized


38/79

IMPACT STRENGTH VERSUS

VARIOUS PROCESSES, HRC 43/45; TL

DIEVAR

200

100

Standard ESR ESR under VAR H ESR+H

H. Lindow38

protective

gas

Material H13;


39/79

e ee e ec onDIEVAR

CuQRO90S

thand uper or

ORVAR S

Orvar 2MVidar Superior

tstren

ghness

g

ep-/

ho

ity-tou

Vidar Superior, Dievar

Elmax

c

tofcr

Ductil

Erosion / Corrosion Thermal Fatigue (Heat Checking)Produ

H. Lindow39


40/79

DESIGN

Influence on:

Erosion Soldering

Corrosion Thermal fatigue cracks Heat cracks Chipping Gross cracks

e eas ng mar s Temper back at cavity wall

H. Lindow40


41/79

Un-suitable Parameters Due To Wrong Design

Gate area

Make the most suitable gate design Avoid an un-suitable relation of melt volume

Avoid an un-suitable relation gate area to runner Avoid an gate opening too small or too big

, ,melt velocity, plunger diameter and its velocity

Location of the gate area

Put right relation of gate section to runner section

H. Lindow41


42/79

Basic Rules For Gate Location

Try to avoid premature cavity erosion Avoid creation of hot spots

Choose most direct ath what means fill awa from ate first 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 causemore 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

H. Lindow42


43/79

g

tim

fillin

hoo

s

F

irst

H. Lindow43


44/79

ng me epen en n o y ng empera ureOf The Al-Alloy

Al 99 9 % 658 C 0 C Furnace tem .

DIN GB USA-ASTM ASIA-JIS EURO NORMDINDIN GBDIN GBDIN USA-ASTMGBDIN USA-ASTMGBDIN ASIA-JISUSA-ASTMGBDIN EURO NORMASIA-JISUSA-ASTMGBDIN

226 G-AlSi9Cu3 LM 24 A380,0 ADC10 (12) EN Al 46000230 G-AlSi12 LM 6 AC3A EN AL44300231 G-AlSi12(Cu) LM 20 A413 ADC1 EN Al 47100

H. Lindow44

239 G-AlSi10Mg LM 9 AC4A EN Al 43000


45/79

-

H. Lindow45


46/79

And Die Preheating Temperatures

-

Die Temp CSm mmFilling Time msAlloy

280

280

1

6

-

12 - 17

60 - 90

-

Mg-Alloy

350

350

,

2,16

3,43

50

60

Die preheating temperatures

Pb, Sn 120 C Zn 150 200 CAl 180 260 C Mg 250 330 C

Cu-Alloys 300 - 350 C

H. Lindow46


47/79

-

H. Lindow47


48/79

Average Recommendedwall thickness

mm

filling timesms

123

12 to 1725 to 4840 to 60

45

6

48 to 7055 to 80

60 to 90

H. Lindow48


49/79

Sm=Wa4

Cw

w , ,

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

H. Lindow49


50/79

Tem erature Increase At Cavit Wall

Dependent On Melt Velocity At The Gate

gate

locity

a

M

eltve

H. Lindow50

Temperature increase


51/79

Gate Velocitya g ve oc ty or parts w t t n

wall

b) Al 20 to 60 m / smin. 18 m / se.g. 33 m / s for Sm = 6 mmVacuum 15 to 30 m / s

c) Mg 40 to 90 m / smin. 27 m / s

=. .d) Zn 30 to 50 m / s

min. 12 m / s

. .e) Cu 20 to 50 m / s

Too high a velocity may damage the die by erosion, soldering, corrosion and also fatigue

H. Lindow51


52/79

Formula For Gate Area

Sa = V tfx waSa =Sa V=S

H. Lindow52


53/79

Gate Area For Parts More Than 150 g

x = gk x p a mm

b = width of gated = gate opening

Wp = velocity plunger

Agk = area plunger a= ve oc y me a ga e

H. Lindow53


54/79

e oc y s on

Al die casting

below 3 m s

Mg die casting

below 4,5 m / s

=g g

= =gafter gate; Agk = area plunger;

t = filling time

H. Lindow54


55/79

Tab

l

u

idin

3G

15

6

4


Relation Gate Area to Volume De endent On


56/79

Relation Gate Area to Volume De endent On

Average Wall Thickness, Gate Opening, Alloy

Averagewall thickness

Gateopening

Relation Sa/ V (mm / cm)Type of Alloy

u n

1,5 0,9 1,48 1,66 3,57 1,77,2,02,53 0

,1,01,11 2

,0,940,690 54

,1,040,78

,

2,411,75

,

1,160,86

3,54,0

4 5

1,31,4

1 5

0,440,37

0 32

0,490,41

0 36

,1,150,98

0 86

,0,580,49

0 435,05,56,0

1,71,82,0

0,300,270,25

0,330,290,25

0,790,710,65

0,400,350,33

H. Lindow56


57/79

Genera A vise For Gate Opening

Finding of gate opening (general rules)

Al die casting 1,0 to 2,5 mm

AlSi min. 1 mm

>>Si > 1 mm

AlSiCu min. 1,2 mm

Mg die casting 0,6 to 2 mm

Zn die casting 0,35 to 1,2 mm

ZnAl4 (Zamak 3) 0,35 to 0,8 mm

ZnAl4Cu1 (Zamak 5) 0,5 to 1,2 mm

Cu die casting 1,5 to 3,0 mm

H. Lindow57


58/79

Formula For Gate Opening In Al Die Casting

d = 0 52 + 0 28 x S

, , m(for 1 < Sm < 4,5 mm)

d = Sm

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

H. Lindow58


59/79

H. Lindow59


60/79

20-35

H. Lindow60


61/79

H. Lindow61

SAL=1 5xB AK0=2 SA


62/79

L=1 5xB K0 A

part

B BR 35

LK0

R 0,5BSame distance

AK1=2AKo

1/3

R

/3L

Same distanceK2 K0

AK=4 AK0 = AK2

H. Lindow62

AK0=2 SA R not bigElse fills at first


63/79

H. Lindow63

1 / 2 D


64/79

/

3

H. Lindow64


65/79

H. Lindow65


66/79

Cavity wall temperature control byinternal cooling

Influence on:

Thermal fatigue cracks Thermal stress cracks Thermal ex ansion Releasing marks Soldering Erosion Corrosion

H. Lindow66

Surface Temperature


67/79

Surface temperature dependents on

Zn 450 CMg 670 C (low heat capacity)

AlSi12(Cu) 680 720 C (high heat Capacity)Ms 970 C

b Cavit contour and die desi n-wall thickness cores

Bad heat transfer

Good heat transferc) Die preheating Temperature

d) Frequency of cyclese) Position of joint contour of both die parts

f) Condition of die filling as filling time, melt velocity,

plunger velocity; metal flow in the cavityg) Die internal cooling heating system; lubrication;

Bad heat transfer

h) Cast system (gate, runner, bush) its design and location; number of overflows


decrease or increase the die life by 30 to 50 %


68/79

s mu a on program w e e p u or n ngwhere the cooling channels should be placed

H. Lindow68


69/79

Temperature profile

Simulation curves for

H. Lindow69

a en w an n rare amera


70/79

Hot spots

Hot s ots causin : Product orosit Solderin Earl heat checkin

H. Lindow70

Corrosion / Erosion

Tem erature Flow In Vertical Direction


71/79

H. Lindow71


72/79

a) Better to have more small cooling channels than a few big ones

b When usin water 9 to 12 mm when usin oil 12 to 15 mmc) Distance cooling channel to cavity in general 25 mm, gate area 28 mm

d) Cooling channel depending on wall thickness of the part

e Distance of coolin channels, max 3 x

H. Lindow72

n erna oo ng arrow a s


73/79

n erna oo ng arrow a s

n narrow areas use u- ar

connected to a cooling channel

in a cylindrical area

Use Cu-paste for heat transfer

from Cu-bar to cylindrical wall(clearance 0.05 0.1 mm,

Ra


74/79

H. Lindow74


75/79

H. Lindow75


76/79

They should not be put at the gate area!

H. Lindow76

Desi n Of Ventin


77/79

Put venting as much as possible but as less as necessary

H. Lindow77


78/79

H. Lindow78


79/79

, .

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Tj-Ningbo.materialDesignUddLayout [Automatisch Gespeichert]