Investigation and Improvement Strategies for Mold Fracture: A Study on the Application of a Pulse Electrodeposition Method for Enhancing Mold Lifespan

Abstract

An investigation on the fracture of a mold, comparing it with a normal part using specific techniques, such as EDX, SEM, and AES, is presented in this study. The EDX analysis revealed that the composition of the normal part was consistent with that of low-carbon steel, mainly comprising Fe and C. In contrast, the fractured part exhibited cracks due to nonconforming nonmetallic inclusions and reticular carbides, with fractures resulting from microporosity agglomeration and cleavage fracture. The SEM and AES analyses further presented the causes of mold fracture, highlighting the mechanism by which the dimples on the specimen edge contributed to the fracture. The EDX analysis confirmed that the mold experienced thermal brittleness during use. To enhance mold durability and extend its lifespan, a pulse electrodeposition method was employed to create a NiCo alloy coating as a replacement for the Cr layer on the metal surface. The coating exhibited a smooth and scratch-free surface. The prepared NiCo special coating significantly increased the mold yield strength by approximately 313.8%, facilitated a 13% increase in plastic deformation, and reduced the fracture strain by 25%, effectively preventing mold fracture and improving its service life.