The Welding Loss Phenomenon Of Aluminum Shell Die Casting Mold
Mold is an important equipment for large-scale production in modern industry. Generally, the materials used for die-casting are aluminum, magnesium, zinc, etc., of which more than 80% are die-cast aluminum alloy shells. About 80% of aluminum alloy shell die-casting is used in the automotive industry. Therefore, the technological trends of the automotive industry influence the manufacturing and output of die-casting molds.
In recent years, with the development of my country’s automobile industry, the demand for aluminum-magnesium alloy die-casting for automobiles has gradually increased. Therefore, considering the large-scale, low-cost, and efficient production of alloy die-casting, while shortening the maintenance time of the mold, the development and introduction of new heat as the mold material, the optimization of the structure and performance of the mold material through heat treatment, and the extension of the life of the mold through surface treatment are already widespread The material is in the die casting process.
The filling time of the cavity is generally 0.1s or less, and the speed of the alloy passing through the gate is about 40-60m/s, and some even reach 200m/s. The compressive strength during metal solidification is usually about 40 to 120 MPa. When the aluminum alloy shell is die-casting, the working surface temperature of the die-casting mold will generally rise to 500~600. When manufacturing small aluminum alloy shell parts, the die-casting-solidification cycle time is about 3~6s, and large aluminum alloy shell parts are also under 90s.
At the beginning of each die-casting cycle, the mold cavity must be rapidly heated by the high-temperature melt, and compressive thermal stress is generated on the working surface; after the die-casting, lubricant is sprayed into the mold for quenching, so tensile stress is generated on the surface. Under the action of this alternating thermal stress, thermal fatigue micro-cracks are generated on the surface of the mold. With the increase of the number of die-casting cycles, the micro-cracks develop rapidly, and some centripetal parts expand to form cracks. The cleaning and corrosion of the mold cavity by the fused gold at the same time around the cracks will further damage the surface of the mold, and eventually lead to early cracks and scraps of the mold.
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