目的 解决一体化压铸模具服役寿命较低的问题。方法 结合宏观形貌观察、服役工况数值仿真、显微硬度测试、金相及扫描电镜观察,以及能谱元素分布分析,系统揭示其失效机理并提出改进措施。结果 内浇口与滑芯块区域为最易失效区,局部峰值温度为550~600 ℃,表层最大软化率约18%,软化层厚度约2 mm;表层显微组织以针状马氏体为主,平均晶粒约5 μm,未见明显再结晶或晶粒粗化。裂纹呈树枝状扩展并伴随铝液渗入,未开裂区域中Al渗入深度约60 μm;渗碳层有效深度约850 μm,但表层C、Si、Fe在约60 μm范围内显著降低,O含量升高,Ni含量基本稳定,显示良好抗氧化性能。高温试验结果表明,H13钢在500 ℃以上显著软化,强度下降明显。结论 压铸模具裂纹主要为由热-力耦合作用引起的疲劳开裂,而表面性能退化则主要源于铝液侵蚀和氧化作用导致C、Fe、Si元素含量降低;相比之下,Ni元素表现出良好的抗氧化性,其含量未发生显著变化。通过在模具表层采用抗高温软化且抗氧化能力强的材料（如Ni基合金）进行增材强化,并优化冷却水道以降低表面峰值温度和温度梯度,可有效减缓热疲劳裂纹萌生及铝液侵蚀,从而提升模具服役寿命与可靠性。
Abstract
The work aims to address the limited service life of integrated die-casting molds. Macroscopic morphology observation, service condition numerical simulation, microhardness testing, metallographic and scanning electron microscopy (SEM) observation, and energy-dispersive spectroscopy (EDS) elemental analysis were combined to systematically reveal the failure mechanisms and propose targeted improvement measures. The inner gate and sliding core block regions were identified as the most failure-prone areas, with local peak temperatures of approximately 550-600 ℃. The maximum surface softening reached about 18%, and the softened layer thickness was approximately 2 mm. The surface microstructure was dominated by acicular martensite with an average grain size of 5 μm, with no significant recrystallization or grain coarsening observed. Cracks exhibited dendritic propagation accompanied by aluminum penetration, with Al infiltration depth in the uncracked regions of approximately 60 μm. The effective carburized layer depth was about 850 μm, whereas surface C, Si, and Fe contents were significantly reduced within 60 μm, and O content increased, indicating surface oxidation and Ni content remained essentially stable, demonstrating good oxidation resistance. High-temperature tests indicated that H13 steel softened significantly above 500 ℃, resulting in a notable decrease in strength. Cracks in die-casting molds are primarily caused by fatigue under thermo-mechanical coupling, while surface degradation is mainly attributed to aluminum erosion and oxidation-induced depletion of C, Fe, and Si. In contrast, Ni exhibits good oxidation resistance with negligible change in content. Employing high-temperature- softening-resistant and oxidation-resistant surface materials (e.g., Ni-based alloys) for additive surface reinforcement, combined with optimized cooling channels to reduce surface peak temperature and thermal gradients, can effectively slow the initiation of thermal fatigue cracks and aluminum erosion, thereby enhancing mold service life and reliability.
关键词
一体化压铸模具 /
失效分析 /
疲劳裂纹 /
工况仿真 /
增材制造 /
铝液侵蚀
Key words
integrated die-casting mold /
failure analysis /
fatigue cracks /
service condition simulation /
additive manufacture /
molten aluminum erosion
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