Micro-Particle Anti-Sticking Technology for Die-Casting Molds | Reduce Soldering & Erosion

Using Micro-Particle Anti-Sticking Technology to Improve Die-Casting Mold Soldering and Erosion Defects

Technical Overview

During prolonged exposure to molten alloys, die-casting molds often suffer from soldering and erosion. These defects roughen the surface, cause cracking, shorten mold life, and degrade product quality.

Power Micro International combines micro-particle surface modification with an anti-sticking IF-WS₂ coating to enhance heat resistance and fatigue strength, dramatically reducing metal adhesion and surface damage.

◆ Technical Principle

1. Micro-Particle Surface Modification

High-hardness multi-alloy nanoparticles are accelerated in a pressurized gas stream to impact the mold surface, forming a nano-scale plastic deformation layer with residual compressive stress. This layer increases hardness, crack resistance, and fatigue life against the high-pressure, high-speed molten flow and thermal cycling.

2. Fullerene-Like IF-WS₂ Anti-Sticking Coating

The fullerene-like tungsten disulfide (IF-WS₂) nano-balls are electrochemically deposited as a thin solid-lubricant film. With an ultra-low friction coefficient (μ≈0.03–0.06), the coating suppresses chemical reactions between molten alloy and tool steel, preventing soldering and adhesion.

◆ Mechanism & Improvement

Soldering:* prolonged contact between molten Al/Zn/Mg alloys and the mold surface forms intermetallic layers (Al–Fe, Al–Si), causing adhesion and tearing.

Erosion:* high-speed flow and temperature gradients trigger mechanical abrasion and chemical attack, producing roughness and cracks. The micro-particle layer plus IF-WS₂ coating jointly reduce these reactions, maintaining a stable smooth surface.

◆ Case Study

In an automotive aluminum die-casting mold:

Tool lifetime extended by over 2×
Molten-metal adhesion reduced by ≈ 80 %
Surface roughness kept below Ra 0.4 µm
Maintenance interval improved from weekly to monthly

Application Areas

◆Aluminum Die-Casting Parts

Used in engines, transmissions, suspensions, electronic heat sinks, and industrial components, offering lightweight and thermal-conductive advantages.

◆Zinc Die-Castings

Ideal for appliances, decorative hardware, and electronic housings with fine surface finish and precision.

◆Magnesium Die-Castings

Applied in automotive, aerospace, and 3C product casings, combining light weight with rigidity.

◆Advantages & Limitations

Applied in automotive, aerospace, and 3C product casings, combining light weight with rigidity.

Item	Advantages	Limitations
Anti-Soldering	Inhibits intermetallic reaction	Longer process time
Anti-Erosion	Hard surface resists fatigue	Work size ≤ 1000 × 1000 mm
Cost Efficiency	Longer life, less downtime	Higher initial cost
Compatibility	Works with nitriding/PVD	Complex shapes need customization

Q&A

Q1： Difference from nitriding or PVD coating ?

It forms both a hard layer and compressive stress, combining fatigue resistance with lubrication.

Q2：Does IF-WS₂ affect dimensions or finish？

No, its 200–400 nm thickness keeps surfaces smooth and precise.

Q3：Can it combine with other coatings？

Yes, it integrates with TiN or CrN for multi-layer protection.

Q4：Applicable materials？

Tool steels such as H13, SKD61, 8407.

Q5：Key benefits？

Longer service life, reduced downtime, and higher yield.

Conclusion & Contact

As precision and surface quality demands rise, the micro-particle reinforcement with anti-sticking coating is vital for longer mold life and stable mass production.

Power Micro International Company offers comprehensive surface-engineering and anti-adhesion solutions to eliminate soldering/erosion defects and enhance productivity.

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