Die cast mold
Heat treatment is important for extending the life of aluminum die casting dies

First, aluminum die-cast molds are affected in a complex manner by factors such as being thermally affected by repeated heating and cooling during casting, pressure during casting, mold shape/material, quenching and tempering conditions, the surface treatment method, and machining. These factors can cause damage such as heat cracks, melting damage, and seizure. Among these damage factors, quenching, tempering, and the surface treatment method are particularly important.
Such aluminum die-cast molds are mainly made of alloy tool steel for hot dies, and since strength that can withstand many large parts and harsh impacts is required, SKD-61 and improved steel grades of SKD-61 with carbon content of 0.6% or less are widely used.
Heat treatment of such mold steel is a very important technology for effectively bringing out the characteristics and mechanical performance of a material, and the performance of the mold differs greatly depending on the quality of the heat treatment. In other words, even molds made of high-grade materials may cause problems during casting unless they are properly heat-treated.
Therefore, by combining Edison Hard treatment (EH-H process) for die casting dies and the quenching developed by our group company Licht Seiko Co., Ltd. that uses a proprietary furnace (engine-driven vacuum pressurized gas cooling furnace/high efficiency vacuum pressurized gas-oil cooling furnace) to perform the treatment, we can contribute to lengthening mold life while taking advantage of the characteristics of surface treatment.

EH-H treatment

EH-H treatment is an aluminum die-cast mold specification that aims to achieve erosion resistance and anti-heat cracking in aluminum.
Edison Hard Hyper (EH-H) is a process of covering the surface of the nitrided layer normally formed by EH treatment with an oxide film of 1 to 3 μm (improved magnetite (Fe3O4) oxide film).

The Black film itself is soft with a hardness of about 300 to 350 HV.
Due to its structure, the mold release agent is first applied neatly and penetrated into the Black film. This exerts a mold release effect and inhibits the affinity with the molten aluminum material to prevent premature seizure.
Image of EH-H
SEM image of Black film Magnification x 10,000
Black film with excellent heat crack resistance

A 3-layer structure has the effect of reducing low cycle thermal fatigue and prevents aluminum material adhesion (seizure), which are causes of heat cracks (checks).

EH-H treatment can be performed by applying a coating type weld overlay of WC + α (tungsten + α) to the areas where melting damage and heat cracks are particularly severe.

Depending on the request, it is possible to improve the releasability by changing the surface roughness of the weld overlay.

External view photograph of EH-H
Corrosion test data of molten aluminum

Sample: SKD-61 (48HRC) ⌀8X100L

  1. ①Only quenching/tempering (no surface treatment)
  2. ②Salt bath nitriding treatment
  3. ③Ion nitriding treatment
  4. ④EH-H treatment
  5. ⑤PVC-TiN treatment

Test conditions: 760℃ molten aluminum (ADC-6)
25scc immersion ⇔ atmospheric cooling 5scc 200 cycles, mold release agent is applied to each sample

Comparison data of anti-heat crack (for casting manufacturer A 800 t class liner)
Comparison between conventional salt bath soft nitriding and EH-H treatment

Material: SKD-61 ESR

Product A
6th mold that underwent EH treatment has no correction at 150,000 shots
Few cracks generated compared to salt bath soft nitriding (about 1/2)
Product B
Product B 2nd and 4th that underwent EH treatment have no correction at 100,000 shots
Few cracks generated compared to salt bath soft nitriding (about 1/4)
*For the 3rd mold, crack welding correction was performed at about 100,000 shots.
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