The Swiss Steel Group, a leading supplier of special steels, has developed the new E 40 K hot-work tool steels, which have been specially designed for high-performance die casting molds. These innovative materials offer improved resistance to thermally induced cracking, longer service life and reduced maintenance intervals - a combination that sets new standards, especially in the automotive sector and other industries with high demands on precision and efficiency.
The die casting process, in which metals are poured into molds under high pressure, generates extreme stresses due to cyclical temperature changes. These often lead to:
- Thermal stresses and surface cracks that affect the quality of the components.
- Shortened service life of the molds, resulting in expensive tool changes and production downtime.
Particularly in the automotive industry, where complex and large-format die-cast parts are required, the demands on materials are increasing in order to ensure high reliability and efficiency.
Innovative materials: High crack resistance and temperature resistance
The new E 40 K hot-work tool steels combine high-temperature strength with exceptional toughness to minimize cracks and slow down their propagation.
Advantages of the new materials:
- Higher yield strength and tensile strength at temperatures between 550 °C and 650 °C compared to conventional materials such as 2343, 2344 or 2367.
- Particularly suitable for high-temperature applications with high demands on load-bearing capacity and wear resistance.
Experimental tests: superior hot tear resistance
The performance of the E 40 K was intensively tested in simulated tests with temperature changes. Samples were heated to 650 °C and then quenched in water to simulate real production conditions.
Results after 8,000 cycles:
- Compared to conventional materials, the new steels showed a 10 mm lower crack depth.
- Microscopic analyses confirmed significantly slower crack propagation.
Practical experience: Longer service life and cost efficiency
The advantages of the E 40 K were impressively confirmed in field tests:
- car keys made of Zamak alloy (Brazil):
- Mold life increased from 300,000 to 700,000 cycles (+233% productivity).
- automotive water pumps:
- Service life increased from 100,000 to 150,000 cycles (+50%).
- streetlight modules:
- Reached 200,000 cycles for the first time (previous materials failed at around 130,000 cycles).
Pioneering solutions for demanding applications
With the new hot-work tool steels, the Swiss Steel Group offers a solution that:
- Extends the service life of die casting molds.
- Guarantees a stable surface quality.
- Reduces operating costs through reduced maintenance intervals.
In addition, the product is available in Green Steel quality, which combines sustainability and high performance. This strengthens the Swiss Steel Group's position as an innovative partner for high-performance production and offers pioneering material solutions for the challenges of modern industry.
