Early Failure Mechanism of Integrated Die-casting Molds

ZHANG Yucheng; LEI Yang; XIE Kai; ZHANG Qiu; LI Zengqing; JIANG Qingshun; WEI Liping

doi:10.3969/j.issn.1674-6457.2026.07.025

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (7) : 270-278. DOI: 10.3969/j.issn.1674-6457.2026.07.025

Advanced Manufacturing Technology and Equipment

Early Failure Mechanism of Integrated Die-casting Molds

ZHANG Yucheng^*, LEI Yang, XIE Kai, ZHANG Qiu, LI Zengqing, JIANG Qingshun, WEI Liping

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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.

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integrated die-casting mold / failure analysis / fatigue cracks / service condition simulation / additive manufacture / molten aluminum erosion

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ZHANG Yucheng, LEI Yang, XIE Kai, ZHANG Qiu, LI Zengqing, JIANG Qingshun, WEI Liping. Early Failure Mechanism of Integrated Die-casting Molds[J]. Journal of Netshape Forming Engineering. 2026, 18(7): 270-278 https://doi.org/10.3969/j.issn.1674-6457.2026.07.025

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