11/10 (Thursday) TECHNICAL PAPER PRESENTATION Annex Hall F203~206 Auditing charge
Session Chairperson
Aisin Keikinzoku Co., Ltd. Shinichi Asai
JD22-01

Effect of various surface treatments on
the soldering and erosion behavior inmolten aluminum alloy
Kawata PE Office● Dr. Kazuki Kawata
Castec Inc. 		 Noriyuki Inatsu, Takasumi Tatsuno,			 Raiichiro Iijima

Various surface treatments have been applied in order to protect
aluminum die-casting molds from damages, such as solderingand erosion in molten aluminum alloy. Among these treatments,
the PVD method for producing various ceramic coatings at low
temperature is a promising process.
We have developed a new AlCrTiSiN-based nano-composite
multilayer coating with excellent wear resistance, heatresistance, and mold release property using a special PVD
facility that can form a dense coating with few defects. The
properties of SKD61 specimens coated with nano-composite
multilayer coatings were compared with those of untreatedspecimens, gas nitrocarburized specimens, gas nitrocarburizedand oxidized specimens, and various coatings prepared via PVD.
Properties such as the hardness, microstructure, crystalstructure, tribological property, and soldering and erosion
resistance in a molten aluminum alloy were compared.
JD22-02

Effects of PVD coating, lubricant andshot peening on die casting dies.
Oerlikon Japan Co., Ltd.
● Takashi Osaki, Fukui Shigeo
YUSHIRO CHEMICAL INDUSTRY CO., LTD.		 Shimizu Yuichiro, Goto Hisanori

With a growing need of automotive lightening, there is a great
demand for Al die cast parts which is lighter and with highdimensional accuracy, as an alternative to steel parts. In orderto improve the price competitiveness of Al die cast parts
and increase its productivity, reducing the downtime andmaintenance time by improving mold life-span is needed. Thefactors contributing to shortening mold life include seizure
heat check and erosion.
We have been receiving a high valuation of PVD coating
the coating technologies which realize longer lives of die
components such as core-pin and insert. We verify theeffect of the combination of PVD coating, lubricant and shot
peening, which enables further life extension.

19 JAPAN DIE CASTING CONGRESS

JD22-03

Erosion Resistance of Cast Steel andSpheroidal Graphite Cast Iron Containing
High Manganese in Molten AluminumAlloys
Graduate School of Engineering Science, Akita University		● Kuzo Goto (Ph. D.)
Akita Industrial Technology Center		 Kengo Kurosawa (Ph. D.)
Hokkou Metal Industry Co., Ltd.		 Masanori Chiba,			 Toshiharu Kon

Erosion of ferrous components such as shot sleeves becomes aproblem in aluminum die casting processes. Our research teamhas been engaged in the clarification of the erosion mechanism.
The obtained results indicated that the saturation solubilityof iron in the molten aluminum alloys is a dominant factor
affecting the dissolution rate of iron through the intermetallic
layers that are formed at the contact interface between themelts and the ferrous materials. Meanwhile, another results
implied that the ferrous materials including high manganese
have good erosion resistance in the melts. In this study, we
conducted the erosion testing of the cast steel and spheroidal
graphite cast iron containing high manganese and other several
ferrous materials. Based on the obtained results, we quantified
the erosion resistance, and investigated the mechanism of theresistance.
JD22-04

The evaluation of Ti matrix composite
shot sleeve for the development
TYK CORPORATION● Sadayasu Takayama,			 Shinji Kajita, Yukie Kaku

We are producing and selling Ti matrix composite shotsleeves having the excellent heat-retaining property foraluminum alloy die-casting. In fact, the sleeve contributes toquality improvement and yield improvement of diecastings
with reduction of cold flakes. In recent years we developed
the harder material and the structure to reduce thermal
deformation and heat load, thereby the life of the sleeve
became more stable and longer.
On this time, we re-evaluate the sleeve through current statusof use at production site and insulation characteristics,
thermal deformation characteristics in experiment for future
further improvement.

Session Chairperson
Advanced Composite Corporation Hideto Sasaki
JD22-05

Die Casting Die Problems and TheirCountermeasures
Hihara consultant office ● Dr. Masahiko Hihara

The trouble of the die casting die accompanied with theoutbreak of a heat checking and the crack associated withthe low cycle thermal fatigue and with contacting at thehigh temperature molten metal (Al, Mg, Zn) and die surface
erosion, wash out and cavitation erosion etc. When thesetroubles occur on the die casting die surface, the causes
many problems such as decrease of the quality of the castingproduct and of the productivity and the increase of theoperation expense. This report describes the improvement
methods for stable die casting based on the analysis of
the current status of die casting die problems, including
examples of heat treatment methods for large scale materials,
application of effective surface treatment and improvement
methods to maintain stable operation.
JD22-06

JD22-07

Achieving High-quality AluminumDie Casting via Cooling Control withAdditively Manufactured 3D Cooling Diesand Preventing Corrosion of CoolingChannels
HIBINO INDUSTRY Co., Ltd.
● Makoto Kato, Masahiro Sugiyama,			 Mitsuhiro Karaki
MEC INTERNATIONAL Co., Ltd. 		 Tsutomu Shibata
Aichi Center for Industry and Science Technology.			 Dr. Eng. Masaki Kato
Aichi Science & Technology Foundation			 Dr. Eng. Hiroaki Iwahori

In order to achieve high-quality aluminum die-casting andprevent aluminum soldering to the surfaces of dies, an insert
die with three-dimensional cooling channels was fabricatedvia selective laser melting method and a nanocarbon coating
effective in improving molten metal fluidity was developed
and applied to the surface of dies. The die was verified capableof being maintained at the optimum temperature via theintermittent water flow control during continuous die casting
operations, and consequently high-quality aluminum die
casting were achieved. Moreover, Ni-P plating was confirmed
effective against the corrosion of the inner surfaces of thecooling channels.

Development of high thermal conductivity
die steel-based powder for 3D printing
Daido Steel Co., Ltd. ● Takashi Yoshimoto, Asako Kamimoto,			 Koichiro Inoue (Ph. D.)

Aluminum die-casting parts, which are effective in reducing
weight and the number of parts, are expected to increase indemand for the electrification of vehicles and carbon neutrality.
Thus, requests for reduction of product failure rate and moldmaintenance, as well as high cycle rate, will also increase.
Die with conformal cooling circuit by 3D printing is one of thesolutions to these problems and its application is expanding.
Conventionally, maraging steel was the only option for 3D
printing powder for molds. On the other hand, maraging
steel has problems such as heat-checking, cracking at watercooling hole, and legal restrictions, and practical applicationof die steel-based 3D printing powder is required. In thispresentation, we report on the development concept of die
steel-based powder with practical performance and the die
characteristics verified by comparison with conventional steels.

JAPAN DIE CASTING CONGRESS 20