HPDC Mold Expert

Material gene compatibility ASSAB DIEVAR’s patented heat treatment process (1020℃ oil cooling + 590℃ double-pass tempering) requires precise control of furnace temperature fluctuations ≤±5℃ to ensure uniform deposition of vanadium carbides, maintaining die core hardness at 46-48HRC under 600℃ conditions. When processed by third parties, equipment temperature variations often reach ±15℃, causing hardness fluctuations>3HRC and reducing high-temperature yield strength by 20% Case ​: The integrated die-casting mold of a car company had a hardness gradient of 4HRC (exceeding the upper limit of the national standard) due to third-party heat treatment, and plastic deformation occurred after 30,000 mold cycles. After Acattech changed to ASSAB’s original treatment, the hardness gradient was ≤1.5HRC, and the service life was increased to 180,000 mold cycles. The cryogenic revolution of 1.2344 ESR by Gleez​ According to acattech, Gleez has developed the ​-196℃×24h cryogenic process, which significantly improves thermal fatigue resistance by promoting complete transformation of martensite (conversion rate 99.5% vs. 97% in conventional process): -Thermal crack initiation cycle: 80,000 mold cycles → 220,000 mold cycles (actual measurement of a new energy vehicle battery tray project) -Reduced thermal expansion coefficient by 18%:4.8×10⁻⁶/K → 3.9×10⁻⁶/K (600℃)

Source: acattech-Baosteel Joint Technology White Paper (2025) Technical breakthrough ​: After acattech gradient tempering, the surface hardness of BPM40 reaches 50HRC (core 42HRC), which solves the problem of high temperature softening of traditional pre-hardened steel

Mechanism of high temperature stability Evolutionary control of carbides ​ When DIEVAR was in service at 600℃, the Mo/V carbide size stabilized at 50-80nm (third-party treatment is easy>200nm), which is the core of its resistance to softening: -Mechanism: Vanadium carbide (VC) nailing grain boundaries and inhibiting dislocation slip -Experimental data: 600℃ yield strength of 1100MPa (30% higher than H13) Junction strengthening technology ​ Gleitz 1.2344ESR reduced the sulfur content to 10ppm by electroslag remelting (ESR) ​​, reducing the grain boundary segregation by 70% and the thermal cracking tendency by 40%: -The crystal boundary energy can be increased: 1.2 J/m² → 1.8 J/m² -Thermal fatigue crack propagation rate: 3.2μm/ 10,000 cycles → 1.5μm/ 10,000 cycles Materialological countermeasures for failure modes​ Thermal fatigue cracking ​ ACATCH recommended the use of gradient tempering technology ​ (cavity surface 580℃→core 520℃) to form a 200MPa compressive stress layer on the surface: -Function: offset the peak thermal stress and increase the crack initiation threshold by 300% -A case of a new energy vehicle enterprise: The maintenance interval of Moren is extended from 30,000 to 80,000 mold times Aluminum liquid erosion ​ Laser cladding in the nozzle area CPM9V (WC-12Co alloy, HV1200): -Erosion rate: 5mg/10,000 mold times → 0.8mg/10,000 mold times -The service life of a steering joint mold is increased by 300%

Disruptive innovation in the pre-processing stage Forging pressure monitoring system ​ Real-time analysis of metal flow direction to ensure ≥4:1 forging ratio (the qualification rate of traditional process is only 68% → acattech reaches 99%): -Technical principle: X-ray real-time imaging + deep learning to predict flow line Angle -Effect: The risk of lateral cracking is reduced by 90% Technological breakthroughs in surface enhancement​

An array of micro pits with a diameter of 50μm and a depth of 10μm is processed on the surface of the gate sleeve -Aluminum flow resistance decreased by 38% -The erosion rate of the nozzle is reduced by 60% (verified by Tesla door structure project)

200,000 accelerated thermal cycles ​ 72 hours of simulated ultra-long life condition (industry standard 50,000 times): -Parameters: room temperature ↔ 700℃ cycle, heating rate 100℃/s (simulated press impact) -Early warning mechanism: automatic trigger of gradient backfire compensation when crack risk is found Aluminum liquid flow field inversion system ​ Reconstruction of the flow velocity field at the gate by computational fluid dynamics (CFD): -Case: The service life of the AlCrN coating area in the gearbox mold pre-increasing area is 220,000 times instead of 120,000 times -Precision: flow rate prediction error <0.5m/s