Case Study

What die materials and fabricated structures could be investigated to allow for semisolid steel forming?

Characteristics required
Thermal shock Thermal fatigue Corrosion Oxidation

Ceramic die materials

Mechanical Strength, Wear, Fatigue

1. She, J., and Ohji, T., Thermal shock behavior of porous silicon carbide ceramics, J. Am. Ceram. Soc., 85, 8, 2002 2. Meyer-Rau, S. and Telle, R., Testing strategies for corrosive interaction of ceramics with semi-solid and molten metal alloys, J. of European Ceramic Society, 25, 2005 3. Evans, H., and Taylor, M., Oxidation of high temperature coatings, J. Aerospace Engineering, IMechE, 220, Part G, 2006 4. Velay, V., et al., A continuum damage model applied to high temperature fatigue lifetime prediction of a martensitic tool steel, Fatigue Fract Engng Struct, 28, 2005.

Ceramic die materials

Partially stabilised zirconia US4279655 (81) and by Mg, Ca or Y additions CA1053709 (79)
Cermet casting mould FR1258926 (Renault)
alumina in Fe, Cr, Al mix; pressed between 7000 and 70,000 psi and sintered between 2190 and 2640 deg F; TBC / lubricants applied: alumina, silica, silico-aluminate, graphite, lamp or acetylene black

Metal die materials H13 tool steel

reduce heat checking by substituting with material with higher elevated mechanical properties reduce magnitude of thermal stress, for example, by increasing the bulk metal die temperature

Ni based super alloys

e.g. INCONEL, Cr-Ni-Mo

Electroslag cast steel

good ductility and toughness as well as high tensile strength at elevated temperatures important for high thermal shock resistance

1. 2. 3.

Sakhuja, A., and Brevick, J., Prediction of thermal fatigue life in tooling for die-casting copper via finite element analysis, Am. Inst. Phys., 2005. Fang, J., et al., The characteristics of fatigue under isothermal and thermo-mechanical load in Cr-Ni-Mo cast hot die steel, Fatigue Fract Engng Struct, 25, 2005. Moon, Y., Kim, J., and Tyne, C., Thermal shock resistance of electroslag cast steel for hot working tools, J. Mat. Proc. Tech., 115-156, 2004.

Die fabtrication methods

Machining from bulk feedstock conventional

Sintering metal and ceramic feedstock

Cladding by shrink fitting GKN Patent US3664411 (73) Multiple layer ceramic similar to LOM principle EP1042803 (2000)
glass & alumina powder sintered into 0.2 mm thick sheets; applicable to metal carbides: B 4C, SiC, & TiC and metal nitrates: Si3N4, BN, & TiN

Sialon ceramic with metal coating JP1011046 (89)

and sialon with metal compound coating film e.g. super hardened Ti, Si, film, by ion planting

Clamped ceramic columns of polygon cross section JP63171239 (88)

applicable with metal oxide or metal nitride (e.g. Si 3N4 and ZrO2)

Mould insert used as cladding WO2006004713 (06)

from developer of melt away core process

Fabricated die structure

Bulk metal

Bulk ceramic
Cermet

Layered structure / Hybrid structure

Channels for heating/cooling cartridges / heat transfer fluid Inserts / shapes that reduce heat build up