Method to evaluate the adhesion behavior of aluminum-based alloys on various materials and coatings for lube-free die casting

Wang, Bo; Bourne, Gerald R.; Korényi-Both, András L.; Monroe, Alex; Midson, Stephen P.; Kaufman, Michael J.

doi:10.1016/j.jmatprotec.2016.06.031

Cited by 16 publications

(10 citation statements)

References 15 publications

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“…In a test, the sample-casting assembly is dismantled usually by a tensile testing machine, and a force required to perform such a process is recorded. This force is a measure of a bonding strength obtained between the sample and the casting material [17,20], i.e., the soldering tendency between paired materials. Examination of their surfaces provides additional information about the soldering process.…”

Section: Introductionmentioning

confidence: 99%

“…Examination of their surfaces provides additional information about the soldering process. Based on the relative movement performed between the sample and the casting during the separation, these tests can be divided into the ejection test [11,17] and the detachment test [20,21]. The ejection test is used for the evaluation of cylindrical pin samples overlapped by the casting, while the detachment is developed for evaluation of flat sample surfaces.…”

Section: Introductionmentioning

confidence: 99%

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The Influence of CrAlN Coating Chemical Composition on Soldering Resistance in Contact with Al-Si-Cu Alloy

Kukuruzović¹,

Terek²,

Kovačević³

et al. 2020

2nd Coatings and Interfaces Web Conference (CIWC-2 2020)

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During the high pressure die casting (HPDC) process the die material is exposed to thermal fatigue, erosion, and corrosion. Corrosion leads to the soldering of cast alloy to tool surfaces which consequently bonds the casting with die material. Besides wear, such a process reduces the casting quality and production efficiency and endangers the tool integrity. Application of thin ceramic coatings on die surfaces reduces the soldering effects and improves the die performance. However, the development of ceramic coatings for these purposes still requires detailed information on the phenomena involved in these processes. In this study, the soldering performance of a complex nanolayer CrAlN coating, with three chemical compositions (high-Cr, balanced Cr:Al, and high-Al content) were evaluated. The cast alloy soldering was evaluated by the detachment test in three configurations. In this test, a simple casting is formed in contact with flat coated surfaces. Upon casting solidification, the formed joint is dismantled, and a force required for this process was recorded. To characterize and quantify the exhibited wear, after the detachment test, surfaces of the coated samples were analyzed by different microscopy techniques. Two forms of wear were detected on investigated samples. Cast alloy soldering processes induced the formation of thin layers of cast alloy on the surfaces of all investigated coatings. Additionally, substrate corrosion through the coating growth defects caused coating layer delamination during the detachment test. The evaluated coatings displayed different behaviors regarding the extent of wear and values of the detachment force. The coating with a balanced CrAlN composition exhibited the best soldering and corrosion resistance and displayed the lowest ejection force. In terms of soldering and corrosion resistance, the high-Al coating outperformed the high-Cr content coating. However, high-Al and high-Cr coating exhibited significantly higher and quite comparable values of detachment force. Based on the quantitative results it was postulated that, besides soldering and substrate corrosion, the casting-coating bonding strength depends also on “pure” sticking effects of cast alloy to coated surfaces.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

The Influence of CrAlN Coating Chemical Composition on Soldering Resistance in Contact with Al-Si-Cu Alloy

Kukuruzović¹,

Terek²,

Kovačević³

et al. 2020

2nd Coatings and Interfaces Web Conference (CIWC-2 2020)

View full text Add to dashboard Cite

show abstract

“…Most studies presented in the literature involve on‐site testing on high‐pressure die‐casting presses submitted to real working conditions; this approach despite being the most accurate is very time consuming and expensive . A common approach in the characterization of die‐casting die materials or their surface modifications is to analyze one single damaging phenomenon at a time such as erosion, soldering, or thermal fatigue.…”

Section: Introductionmentioning

confidence: 99%

Design of a Test Rig for the Characterization of Thermal Fatigue and Soldering Resistance of the Surfaces of Tool Steels for High‐Pressure Die‐Casting Dies

Gobber

Pisa²,

Ugues

et al. 2019

steel research int.

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The conceptualization and development of a test rig able to reproduce thermal stresses and contact with molten aluminum alloy, typical of high-pressure diecasting dies, are described. During the test, a hot-work tool steel sample is cyclically heated by contact with molten aluminum alloy (AlSi11Cu2(Fe)) and then cooled by the spraying of a water-diluted silicone-based lubricant. A finite element method (FEM) simulation is setup to determine the temperature at different depths beneath the sample surface during thermal cycling and is experimentally validated to design the proper sample geometry aimed at reproducing the stress/strain conditions experienced by a die-casting die insert. A tensile-compressive stress state is achievable on the surface of the sample by machining a notch with a suitable radius, which is able to produce a plastic strain comparable with the insert one. A thermally induced stress-strain fatigue loop is determined for both the sample and the component. Temperatures are monitored discontinuously by infrared (IR) thermography after heating and continuously by thermocouples placed at a reference depth of 5.5 mm. Finally, the optimized testing conditions are validated experimentally: both thermal cracking and soldering phenomena are successfully reproduced on a lab-scale test rig.

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“…In order to protect die casting molds, hard coatings deposited by physical vapor deposition (PVD), such as TiN, CrN, (Cr,Al)N, Ti(C,N), Ti(B,N), or (Ti,Al)(C,N) [ 4 , 5 , 6 ] have been employed to act as a physical barrier to the die casting molding to prevent the erosion and soldering of aluminum and improve the resistance against thermal cracking [ 7 ]. Previous studies show that TiN presented good corrosion and erosion wear resistance [ 4 , 5 , 6 ]. However, this coating is not a good solution for HPDC due to its low oxidation temperature [ 4 ].…”

Section: Introductionmentioning

confidence: 99%

“…Previous studies show that TiN presented good corrosion and erosion wear resistance [ 4 , 5 , 6 ]. However, this coating is not a good solution for HPDC due to its low oxidation temperature [ 4 ]. TiAlN and TiSiN coatings exhibit good mechanical properties and also exhibit a better oxidation resistance up to 700 °C, however, their adhesion under substrate is reduced, which leads to sudden failures [ 8 ] during service.…”

Section: Introductionmentioning

confidence: 99%

Tribological and Wear Performance of Nanocomposite PVD Hard Coatings Deposited on Aluminum Die Casting Tool

et al. 2018

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In the aluminum die casting process, erosion, corrosion, soldering, and die sticking have a significant influence on tool life and product quality. A number of coatings such as TiN, CrN, and (Cr,Al)N deposited by physical vapor deposition (PVD) have been employed to act as protective coatings due to their high hardness and chemical stability. In this study, the wear performance of two nanocomposite AlTiN and AlCrN coatings with different structures were evaluated. These coatings were deposited on aluminum die casting mold tool substrates (AISI H13 hot work steel) by PVD using pulsed cathodic arc evaporation, equipped with three lateral arc-rotating cathodes (LARC) and one central rotating cathode (CERC). The research was performed in two stages: in the first stage, the outlined coatings were characterized regarding their chemical composition, morphology, and structure using glow discharge optical emission spectroscopy (GDOES), scanning electron microscopy (SEM), and X-ray diffraction (XRD), respectively. Surface morphology and mechanical properties were evaluated by atomic force microscopy (AFM) and nanoindentation. The coating adhesion was studied using Mersedes test and scratch testing. During the second stage, industrial tests were carried out for coated die casting molds. In parallel, tribological tests were also performed in order to determine if a correlation between laboratory and industrial tests can be drawn. All of the results were compared with a benchmark monolayer AlCrN coating. The data obtained show that the best performance was achieved for the AlCrN/Si3N4 nanocomposite coating that displays an optimum combination of hardness, adhesion, soldering behavior, oxidation resistance, and stress state. These characteristics are essential for improving the die mold service life. Therefore, this coating emerges as a novelty to be used to protect aluminum die casting molds.

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Method to evaluate the adhesion behavior of aluminum-based alloys on various materials and coatings for lube-free die casting

Cited by 16 publications

References 15 publications

The Influence of CrAlN Coating Chemical Composition on Soldering Resistance in Contact with Al-Si-Cu Alloy

The Influence of CrAlN Coating Chemical Composition on Soldering Resistance in Contact with Al-Si-Cu Alloy

Design of a Test Rig for the Characterization of Thermal Fatigue and Soldering Resistance of the Surfaces of Tool Steels for High‐Pressure Die‐Casting Dies

Tribological and Wear Performance of Nanocomposite PVD Hard Coatings Deposited on Aluminum Die Casting Tool

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