Control of Soldering and Thermal Fatigue during Die Casting
The objective of the project is to apply capabilities and technologies developed at
ORNL to control soldering and thermal fatigue of die casting dies. A new high-density infrared (HDI)
processing capability will be developed to apply coatings and surface treatments to die casting dies to prevent soldering and thermal fatigue. Thermodynamic models of soldering during die casting will be developed for use as a tool to predict soldering during die casting.
The HDI coating process was demonstrated on room temperature sprayed and HDI-fused Cr2C# coatings with nickel-based binders on H13 steel pins to test soldering resistance. The coated core pins were tested under industrial conditions at the facilities of TTE Casting Technologies, Oak Ridge, Tennessee. In this study, the coated pin performed significantly better than an uncoated pin even though it was
subjected to significantly higher temperatures due to its position in the die cavity. During this and
other tests no spalling of HDI coating has ever been observed, suggesting that cerment coatings have
inherent advantages over PVD coatings in resisting spalling.
Can be applied to other emerging technologies such as squeeze casting and semi-solid casting.
Less scrap and improved quality and consistency with higher dimensional and surface quality.
Oak Ridge National Laboratory
Steve Udvardy North American Die Casting Association 241 Holbrook Drive Wheeling, IL 60090 website: www.diecasting.org