[Case Study] Improvement of Lifespan through Repetitive Processing of Aluminum Casting Two-Wheel Piston Molds
Mold lifespan is more than three times! A case that led to significant cost savings compared to creating three molds.
Traditionally, gas soft nitriding was used, resulting in defects due to cracks after 10,000 shots, leading to disposal. The causes were thought to be the occurrence of heat checks due to thermal fatigue and metal fatigue caused by warping during forging. After the new Kanack treatment, cracks similarly occurred after 16,000 shots, leading to defects and disposal, but heat checks were suppressed. The updated type avoids operations until cracks occur in the mold's lifespan and enables longer life by repeating reprocessing (removal of residual stress and addition of compressive stress) after 8,000 shots. 【Traditional Issues】 ■ Occurrence of cracks ■ Occurrence of heat checks ■ Metal fatigue *For more details, please refer to the PDF document or feel free to contact us.
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【Processing Effects (Improvement of Surface Hardness)】 ■ After New Kanack treatment, cracks occurred at 16,000 shots, leading to defects and disposal (heat checks were suppressed). ■ The updated type avoids operations until cracks occur in the mold's lifespan and enables extended longevity by repeating reprocessing at 8,000 shots (removal of residual stress and addition of compressive stress). *For more details, please refer to the PDF document or feel free to contact us.
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For more details, please refer to the PDF document or feel free to contact us.
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Kanak processing is a gas nitriding treatment using a unique method. The material is held in a heating atmosphere of around 500°C for several hours, allowing nitrogen to diffuse and permeate from the steel surface, reacting with metal elements to form a hardened layer. Unlike conventional nitriding treatments, there are very few brittle iron nitride compounds near the surface, and the high compressive residual stress and smooth hardness distribution are characteristics of Kanak processing.
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