The die casting company put in a call to Phygen after hearing about how FortiPhy corrosion resistant PVD coatings give better results in extreme conditions and radical tooling applications.
Within a few days they had the pins back and ready for a production run. Running around the clock, the previous pin breakage problems halted production at least every other day for repair and setup.
With the new FortiPhy metal surface coatings, core pins were still like new and going strong after more than 12, shots—well beyond the previous results. This productivity improvement led the company to continue sending core pins to Phygen. After more than 12, shots, we have had no broken core pins. The key to FortiPhy thin-film coatings exceptional toughness, low coefficient of friction, and corrosion resistance is its uniform, nanocrystalline structure. Having solved the uniformity problems inherent in the PVD processes of the past, Phygen can apply thinner coatings that outperform thicker, less-uniform coatings.
In addition, Phygen hard surface coatings are applied at much lower temperatures. As the aluminium and metal die solder or stick together, sticking and dragging of the casting to the die will occur. These areas will appear as indentations and other defects on the casting. Die coatings provide insulating properties to the die and reduce thermal shock during the cast. Thermal shock can lead to a roughness defect on the die called heat checking many small cracks on the die face , which may appear as small protrusions on the casting.
Primarily, die coatings are designed to achieve controlled directional solidification by promoting solidification of the cast metal in one direction. If heat transfer is properly controlled in all the various parts of the die, then directional solidification can be achieved. During the aluminum injection molding process, the same chemical reaction takes place, but with the aluminum and nitrogen coming from different places.
When this occurs, the same expansion occurs, but in an uncontrolled manner, leading not only to surface compression, but cracking as well. Aluminum reacts with nitrogen compounds. The heat of formation for aluminum nitride is These numbers are only somewhat useful, as they depend upon many factors and assumptions including room temperature. But the aluminum nitrides lower delta G value means it is thermodynamically favored to form compared to aluminum carbide.
The reasons for this basic phenomenon gets us to the atomic level of where the effects of atomic sizes, bond structure, electronic valences, and crystalline shape all interact to result in a general reaction strength and mechanism that is indicated by the heat of formation value mentioned above.
Special Decorative Parts Superior Grade Surface finish applicable to limited areas of the casting and dependent on alloy selected; required to have maximum value in micro inches as specified on print. O-Ring Seats or Gasket Areas. About Dynacast Difference Specialty Die Casting Knowledge Center Careers About Dynacast Dynacast, a Form Technologies Company, is a leading global manufacturer of small engineered precision components utilizing proprietary multi-slide die casting technology and tooling techniques.
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