Project Background
Currently, the Engineering Center at Raidy is spearheading a key initiative: enhancing the overall service life and stability of die-casting molds.
The subject of this case study stems from feedback received from a new client in Thailand. This client had previously commissioned three high-pressure die-casting molds from another manufacturer; while the original design life of these molds was rated at approximately 100,000 cycles, actual operational use saw them suffer from abnormal shutdowns and severe structural failures before even reaching the 50,000-cycle mark.
Consequently, the client requested that Raidy conduct a systematic analysis of the critical factors directly impacting the molds’ service life, and subsequently propose a set of actionable improvement solutions.
Summary of Major Failure Issues in High-Pressure Die Casting Molds
Based on field feedback and observations regarding the operational status of high-pressure die casting molds, the primary issues are concentrated in the following areas:
- Severe Erosion at the Ingate Boss Location:
Subjected to prolonged scouring by high-pressure, high-velocity molten metal.
Accelerated surface corrosion and abrasive wear.
Leads to localized structural weakening and recurring instances of mold chipping/spalling. - Severe Wear on Core-Pulling Wedge Blocks:
Insufficient hardness of mating surfaces or material property mismatch.
Prolonged friction results in dimensional instability.
Compromises the stability of the core-pulling mechanism and reduces the overall service life of the die casting mold. - Flash/Burr Issues at the Mold’s “Water Tail” (Flow-End) Area:
Inadequate venting and parting-line sealing structures.
Uneven distribution of mold clamping pressure.
Results in molten metal overflow and the formation of flash/burrs.
Preliminary Technical Assessment and Analysis
Based on the structure of the high-pressure die-casting mold and the characteristics of its failure modes, a preliminary assessment indicates that the issues primarily stem from the following aspects:
- Prolonged high-pressure, high-velocity erosion of the gating system, compounded by metallic corrosion;
- Insufficient localized structural hardness and inadequate wear resistance;
- Failure to apply surface hardening treatments to critical load-bearing and erosion-prone zones;
- Inadequate design of venting and sealing structures, leading to a risk of flash formation.
In particular, the sprue boss and the “water tail” (flow-end) regions represent typical zones subject to severe erosion and high thermal loads; as such, they constitute critical weak points that significantly determine the service life of the high-pressure die-casting mold.
Improvement Recommendations and Technical Solutions
Optimization of the Ingate and High-Erosion Zones
It is recommended to adopt an insert-based structural design for critical erosion zones at the ingate.
Apply surface hardening treatments (e.g., SQP treatment) to localized high-risk areas.
Where necessary, optimize the mold structure to reduce direct impingement angles, thereby implementing a “reduced-impact design.”
Surface Hardening Treatment for High-Pressure Die Casting Molds (SQP Process)
Once dimensional stability is confirmed following mold trials, apply SQP treatment to the critical working surfaces of the high-pressure die casting mold.
Objectives:
Increase surface hardness.
Enhance resistance to erosion.
Delay the onset of early heat checking and fatigue damage.
Particularly suitable for:
Ingates.
Gate areas.
Areas prone to corrosion and high-temperature thermal shock.
Improvements to the Core-Pulling Mechanism
Recommendations for the Wedge Blocks:
Upgrade the material hardness grade or switch to a material system with superior wear resistance.
Optimize the fit clearance and lubrication conditions.
Goal: Reduce long-term frictional wear and enhance operational stability.
Solutions for Flash Issues
Addressing flash issues at the overflow/vent locations:
It is recommended to increase the sealing surface area of the vent blocks.
Improve the fitting precision of the parting line.
Optimize the balance between venting efficiency and clamping pressure.
Enhance localized sealing capabilities to structurally reduce the probability of flash formation.
Verification of Die-Casting Mold Lifespan: Real-World Application Case Studies
Based on our experience with similar projects, whenever clients report “premature cracking issues”—particularly in areas prone to aging or at casting points—we typically implement the following combined strategy:
Once dimensional stability is confirmed during trial runs, we apply localized SQP surface hardening treatments.
For high-stress areas, we incorporate localized inserts or design structures that allow for replaceable components.
By employing this dual approach—combining surface hardening with structural optimization—we significantly reduce the rate of erosion and crack propagation.
Actual application results demonstrate that this methodology effectively delays premature failure in high-pressure die-casting molds, thereby enhancing the stability and longevity of the mold’s overall service life.
Project Outcomes and Future Collaboration
Based on the technical discussions and solution confirmations outlined above, both parties have successfully and efficiently launched three new collaborative projects focused on the improvement of high-pressure die-casting molds. We would like to express our gratitude to our client for selecting Raidy Mold Manufacturer for these new initiatives.
Moving forward, we will continue to deepen our collaboration by focusing on the following key areas:
Enhancing mold lifespan;
Optimizing critical areas prone to erosion;
Implementing dual improvements involving both structural design and material selection.
Collaboration Opportunities
If you are currently seeking:
Solutions for die-casting mold manufacturing and improvement;
Technical support for extending mold lifespan;
Or assistance with existing issues such as mold erosion, cracking, or flash formation;
We invite you to contact Raidy Mold Manufacturer at any time. We are ready to provide targeted engineering analysis and comprehensive solutions to address your specific needs.
