Study of PVD-Coated Inserts’ Lifetime in High-Pressure Die Casting Regarding the Requirements for Surface Quality of Castings
Abstract
:1. Introduction
2. Materials and Methods
2.1. Material of Inserts and Surface Treatment
2.2. Casting and Casting Process Conditions
2.3. Estimation of Hardness of Inserts and Roughness of Bearing Surface of Castings
2.4. Specimen Preparation and Optical Microscopy and SEM
3. Results and Discussion
3.1. Optical Microscopy and SEM Analysis
3.2. Hardness and Surface Roughness
4. Conclusions
- The optical and SEM analysis showed wear and the formation of craters at the bottom, of which the uncovered basic material of the insert is visible. The study of surface morphology revealed the presence of cracks probably caused by the cyclic thermomechanical effect. These failures can be prerequisites for the formation of intermetallic Fe–Al layers. They negatively affect the surface quality of castings, manifesting by increasing average roughness (Ra).
- The PVD-coated inserts achieved a significantly longer lifetime than uncoated inserts concerning the requirements of casting surface roughness (Ra), while the TiN-coated insert performed the best in comparison with TiAlN- and CrAlSiN-coated inserts. The difference in lifetime using TiAlN- and CrAlSiN-coated inserts was only 10,000 shots, with an advantage for TiAlN.
- The polishing performed to prolong the inserts’ lifetime had a minimal effect on the uncoated insert (prolongation of lifetime by 500 shots). It was also applied in the case of TiAlN- and CrAlSiN-coated inserts when they were approaching the critical value of Ra and the prolongation of lifetime ranged from 2000 to 3000 shots.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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C | Si | Mn | Cr | Mo | V | Fe |
---|---|---|---|---|---|---|
0.38 | 0.90 | 0.40 | 5.20 | 1.30 | 0.45 | balance |
Fe | Si | Mn | Ni | Cr | Ti | Cu | Pb | Mg | Zn | Sn | Al |
---|---|---|---|---|---|---|---|---|---|---|---|
max 1.1 | 10– 12 | max 0.55 | max 0.45 | max 0.15 | max 0.25 | 1.5– 2.5 | max 0.25 | max 0.3 | max 1.7 | max 0.15 | balance |
Measured Parameters | Uncoated | CrAlSiN- Coated | TiAlN-Coated | TiN-Coated |
---|---|---|---|---|
Hardness (HRC) | ||||
Mean | 48 | 52 | 53 | 50 |
SD | 0.4 | 0.9 | 1.1 | 0.6 |
Roughness (µm) | ||||
Ra | 0.10 | 0.34 | 0.39 | 0.46 |
Rz | 0.6 | 1.1 | 1.6 | 1.4 |
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Sütőová, A.; Kočiško, R.; Petroušek, P.; Kotus, M.; Petryshynets, I.; Pylypenko, A. Study of PVD-Coated Inserts’ Lifetime in High-Pressure Die Casting Regarding the Requirements for Surface Quality of Castings. Coatings 2024, 14, 1043. https://doi.org/10.3390/coatings14081043
Sütőová A, Kočiško R, Petroušek P, Kotus M, Petryshynets I, Pylypenko A. Study of PVD-Coated Inserts’ Lifetime in High-Pressure Die Casting Regarding the Requirements for Surface Quality of Castings. Coatings. 2024; 14(8):1043. https://doi.org/10.3390/coatings14081043
Chicago/Turabian StyleSütőová, Andrea, Róbert Kočiško, Patrik Petroušek, Martin Kotus, Ivan Petryshynets, and Andrii Pylypenko. 2024. "Study of PVD-Coated Inserts’ Lifetime in High-Pressure Die Casting Regarding the Requirements for Surface Quality of Castings" Coatings 14, no. 8: 1043. https://doi.org/10.3390/coatings14081043