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Premature thermal fatigue failure of aluminium injection dies with duplex surface treatment

Corujeira Gallo, Santiago, Figueroa, Carlos A and Baumvol, Israel J R 2010, Premature thermal fatigue failure of aluminium injection dies with duplex surface treatment, Materials science and engineering A, vol. 527, no. 29-30, pp. 7764-7769, doi: 10.1016/j.msea.2010.08.048.

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Title Premature thermal fatigue failure of aluminium injection dies with duplex surface treatment
Author(s) Corujeira Gallo, Santiago
Figueroa, Carlos A
Baumvol, Israel J R
Journal name Materials science and engineering A
Volume number 527
Issue number 29-30
Start page 7764
End page 7769
Total pages 6
Publisher Elsevier
Place of publication Amsterdam, The Netherlands
Publication date 2010-11-15
ISSN 0921-5093
Keyword(s) H11 steel
Aluminium injection
PVD coating
Thermal fatigue
Surface contamination
Summary The premature failure of an aluminium injection die with a duplex surface treatment (plasma nitriding and physical vapor deposition coating) was investigated, in an effort to identify the causes of such premature failure of the component. The manufacturing and the operating conditions were documented. Analytical tools were used, including scanning electron microscopy with energy dispersive X-ray capability, X-ray diffraction, and instrumented microhardness testing. Preliminary observations showed a microstructure of coarse tempered martensite, and a considerably rough surface with porosity and cracks. A detailed analysis of crack initiation sites identified sulfur inclusions in the subsurface, underneath the coating. A further revision of the processing conditions revealed that a sulfur-impregnated grinding stone had been used to polish the die. The chemical composition of such grinding stone matched that of the inclusions found in the subsurface of the failed component. Thus, searched causes of premature failure could be discussed on the lights of the present findings.
Language eng
DOI 10.1016/j.msea.2010.08.048
Field of Research 091207 Metals and Alloy Materials
091299 Materials Engineering not elsewhere classified
091399 Mechanical Engineering not elsewhere classified
Socio Economic Objective 869999 Manufacturing not elsewhere classified
HERDC Research category C1.1 Refereed article in a scholarly journal
Copyright notice ©2010, Elsevier
Persistent URL http://hdl.handle.net/10536/DRO/DU:30088205

Document type: Journal Article
Collection: Institute for Frontier Materials
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