[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, and defects due to cracks occurred 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 also occurred after 16,000 shots, resulting in defects and disposal, but heat checks were suppressed. The updated type avoids operations until crack occurrence 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 materials or feel free to contact us.
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【Processing Effect (Improvement of Surface Hardness)】 ■ After New Kanak treatment, cracks occurred after 16,000 shots, resulting in defects and disposal (heat checks were suppressed). ■ The updated type avoids operations until crack occurrence in mold life and enables longer lifespan 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 from the surface of the steel and react 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 along with a smooth hardness distribution are characteristics of Kanak processing.