The objective of this research was to investigate a new test procedure for simulating the temperatures in die casting so that materials can be evaluated as tool materials for the high-pressure die casting of aluminium. Other procedures have been used for evaluating the thermal fatigue performance of tool materials, but these tests do not reproduce all the conditions found in production environments. A new test method has been established that enables the thermal fatigue resistance of materials to be identified. The test is robust, reliable, and versatile and has a large operating temperature range (25–1200°C), and the cycle times and dwell times are adjustable. The results have shown a similar number of cycles to induce the same level of fatigue cracking as in actual die-casting tools. The performance of different materials can be compared, and an approximate fatigue life for high-pressure die-casting tools can be determined.
ChenZ. W.Formation and progression of die soldering during high pressure die casting. Int. J. Mater. Sci. and Engng, 2005, A397, 356–369.
2.
GuliziaS.JahediM. Z.DoyleE. D.ChenZ. W.Application of duplex surface treatments for aluminium high pressure die casting tools. Tooling 1999 Conference Proceedings, Melbourne Institute of Materials Engineering, Australia, 1999, pp. 205–210.
3.
SjoströmJ.BergströmJ.Thermal fatigue testing of chromium martensitic hot work tool steel after different austenitising treatments. J. Mater. Processing Technol., 2004, 153–154, 1089–1096.
4.
WallaceJ. F.WangY.SchwamD.Effect of composition and processing on the thermal fatigue and toughness of high performance die steelsDie Casting Engr, September-October 1997, 41, 26–32.
5.
WallaceJ. F.XiaofengS. U.SchwamD.Die materials of critical applications and increased production of castings. Die Casting Technology for the New Century 2000 Transactions, Rosemont, Illinois, 6–8 November 2000 (North America Die Casting Association (NADCA)).
6.
XiaoxiaH.HuaY.YanZ.FuzhenP.Effect of Si on the interaction between die casting die and aluminium alloy. J. Mater. Lett., 2004, 58, 3424–3427.
7.
ZhuY.SchwamD.WallaceJ. F.BirceanuS.Evaluation of soldering, washout and thermal fatigue resistance of advanced metal materials for aluminium die-casting dies, Int. J. Mater. Sci. and Engng., 2004, A379, 420–431.
SchwamD.WallaceJ. F.BirceanuS.Effect of design factors on thermal fatigue cracking of die casting dies, Final report, Department of Materials Science, Case Western Reserve University, Cleveland, Ohio, Project DE-FC07-00ID138486, US Department of Energy, Washington, DC, October 2004.
10.
NovovicD.DewesR. C.AspinwallD. K.VoiceW.BowenP.The effect of machined topography and integrity on fatigue lifeInt. J. Mach. Tools and Mf., 2004, 44, 125–134.
11.
PerssonA.Tool failure in die casting. Doctoral Thesis, Department of Materials Science, Uppsala University, 2003.
12.
SrivastavaA.A multilayer coating architecture to reduce heat checking of die surfaces. Int. J. Surf. and Coatings Technol., 2003, 163–164, 631–636.
13.
SrivastavaA.JoshiV.ShivpuriR.Computer modelling and prediction of thermal fatigue cracking in die-casting toolingInt. J. Wear, 2004, 256, 38–43.
14.
OliveS.Long-life die designDiecasting World, 2005, 14(1), 15.
15.
BendykJ. C.MaraczO. J.WallaceJ. F.Thermal fatigue behaviour of die materials for aluminium die casting. 6th SDCE International Die Casting Congress, Cleveland, Ohio, 16–19 November 1970, paper 111, pp. 1–20.
WerońskiA.HejwoskiT.Thermal fatigue. In Thermal fatigue of metals, 1991, pp. 108–135 (Marcel Dekker, New York.
18.
WorbyeJ.New information points the way to longer die casting die life. Die Casting Engr, 1985, 29(4), 42–54.
19.
HartmanG.A thermal control system for thermal cycling. J. Test Evaluation, 1985, 13(5), 363–366.
20.
TairaM.FujinoM.OhtaniR.Collaborative study on thermal fatigue properties of high temperature alloys in Japan. J. Fatigue and Fracture Engng Mater. and Struct., 1979, 1, 495–508.
21.
FissoloA.MariniB.NaisG.WidentP.Thermal fatigue behaviour for a 316L type steel. J. Nucl. Mater., 1996, 233–237 (1), 156–161.
22.
PerssonA.HogmarkS.BergstromJ.Thermal fatigue cracking of surface engineered hot work tool steels. Int. J. Surf. and Coatings Technol., 2005, 191, 216–227.
23.
KawamotoM.TanakaT.NakajimaH.Effect of several factors on thermal fatigue. J. Mater., 1966, 1 (4), 719–758.
24.
GlennyE.NorthwoodJ. E.ShawS. W. K.TaylorT. A.A technique for thermal-shock and thermal-fatigue testing based on the use of fluidised solids. J. Inst. Metals, 1959, 87, 294–302.
25.
Fatigue and fracture, Vol. 19, 1996, (American Society for Metals, Metals Park, Ohio).
26.
CastelliM. G.EllisJ. R.Improved techniques for thermo-mechanical testing in support of deformation modeling. In Thermo mechanical fatigue behavior of materials (Ed. SenitogluH.), 1993, pp. 195–211 (American Society for Testing and Materials, Philadelphia, Pennsylvania).
27.
Van HeerdenC.NobelA. P. P.Van KrevelenD.W.Mechanism of heat transfer in fluidized beds. Industrial and Engng Chem., 1953, 45(6), 1237.
28.
MowbrayD. F.McConneleeJ. E.Nonlinear analysis of a tapered disk thermal fatigue specimen, In Thermal fatigue of materials and components, 1976, pp. 10–29 (American Society for Testing and Materials, Philadelphia, Pennsylvania).
29.
PerssonA.HogmarkS.BergstromJ.Simulation and evaluation of thermal fatigue cracking of hot work tool steels. Int. J. Fatigue, 2004, 26, 1095–1107.
30.
PerssonA.HogmarkS.BergstromJ.Temperature profiles and conditions for thermal fatigue cracking in brass die casting dies. J. Mater. Processing Technol., 2004, 152, 228–236.
