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molds
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Published: 15 May 2022
Fig. 35 Examples of common ejection components for injection molds
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.steel.c0089617
EISBN: 978-1-62708-232-7
... Abstract A forged 4130 steel cylindrical permanent mold, used for centrifugal casting of gray- and ductile-iron pipe, was examined after pulling of the pipe became increasingly difficult. In operation, the mold rotated at a predetermined speed in a centrifugal casting machine while the molten...
Abstract
A forged 4130 steel cylindrical permanent mold, used for centrifugal casting of gray- and ductile-iron pipe, was examined after pulling of the pipe became increasingly difficult. In operation, the mold rotated at a predetermined speed in a centrifugal casting machine while the molten metal, flowing through a trough, was poured into the mold beginning at the bell end and ending with the spigot end being poured last. After the pipe had cooled, it was pulled out from the bell end of the mold, and the procedure was repeated. Investigation supported the conclusion that failure of the mold surface was the result of localized overheating caused by splashing of molten metal on the bore surface near the spigot end. In addition, the mold-wash compound (a bentonite mixture) near the spigot end was too thin to provide the proper degree of insulation and to prevent molten metal from sticking to the bore surface. Recommendations included reducing the pouring temperatures of the molten metal and spraying a thicker insulating coating onto the mold surface.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001378
EISBN: 978-1-62708-215-0
... Abstract Two 38 mm (1.5 in.) diam threaded stud bolts that were part of a steel mold die assembly from a plastics molding operation were examined to determine their serviceability. Chemical analysis showed the material to be a plain carbon steel that approximated 1045. Visual examination...
Abstract
Two 38 mm (1.5 in.) diam threaded stud bolts that were part of a steel mold die assembly from a plastics molding operation were examined to determine their serviceability. Chemical analysis showed the material to be a plain carbon steel that approximated 1045. Visual examination revealed evidence of severe hammer blows to the clevis and boss areas and a gap between the die and the underside of the boss. Magnetic particle inspection showed cracks at the thread roots that, when examined metallographically, were found to contain MnS stringers. The cracking of the threads was attributed to a poor stud bolt design, which allowed a high stress concentration to occur at the base of the threads upon application of a lateral load. It was recommended that bolts of a new design that incorporated a stress-relieving groove be used. Threading of the bolt to eliminate the gap between the lower face of the boss and the die and an improved method of inserting or removing the bolt to avoid hammering (use of a wrench on a square or hexagonal boss) were also recommended.
Image
Published: 15 May 2022
Fig. 4 Four-cavity (2+2) family injection mold shown opened on the bench with molded parts from the mold in white ABS material. Photo courtesy of Quality Molding, Inc., Somerset, WI, USA
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Image
Published: 15 May 2022
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001852
EISBN: 978-1-62708-241-9
... Abstract A 2–3 mm thick electroformed nickel mold showed early cracking under thermal load cycles. To determine the root cause, investigators obtained monotonic and cyclic properties of electroformed nickel at various temperatures and identified possible fatigue mechanisms. With the help...
Abstract
A 2–3 mm thick electroformed nickel mold showed early cracking under thermal load cycles. To determine the root cause, investigators obtained monotonic and cyclic properties of electroformed nickel at various temperatures and identified possible fatigue mechanisms. With the help of finite element modeling, they analyzed the material as well as the design and in-service application of the mold. They discovered that overconstraining the mold, while it was in service, caused excessive thermal stresses which accelerated crack initiation and propagation. Investigators also proposed remedies to prevent additional failures.
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Published: 01 January 2002
Fig. 9 Plastic mold die made from AISI S7 tool steel that was found to be cracked before use. A crack followed the lower recessed contour of the large gear teeth and had an average depth of 1.6 mm ( 1 16 in.). Smaller cracks were also observed on the flat surfaces. (a) Actual size
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Image
Published: 01 January 2002
Fig. 19 AISI P20 mold made from prehardened stock that was carburized and rehardened. After heat treatment, it was found to be cracked (arrow). See also Fig. 20 .
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Image
Published: 01 January 2002
Fig. 20 Metallographic section from the AISI P20 mold shown in Fig. 19 . (a) Top part of a macroetched (10% aqueous nitric acid) disk cut from the mold revealing a heavily carburized case. Actual size. (b) Micrograph showing gross carbide buildup at the surface with an underlying region
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Published: 01 January 2002
Fig. 20 The DSC thermogram representing a molding resin pellet that had produced brittle parts. The thermogram shows a major melting transition associated with nylon 6/12 and a weaker transition attributed to polypropylene.
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Published: 01 January 2002
Fig. 21 The DSC thermogram representing a second molding resin pellet that had produced brittle parts. The thermogram shows a major melting transition associated with nylon 6/12 and a weaker transition attributed to nylon 6/6.
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Published: 01 January 2002
Fig. 28 (a) AISI 420 stainless steel mold containing a defect (arrow) observed after polishing the inside diameter surface. (b) Microscopic examination revealed a large silicate inclusion (unetched).
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Image
Published: 01 January 2002
Fig. 38 (a) Pitting on this mold cavity (arrow) was observed after polishing of the AISI S7 plastic mold and was caused by the use of improper post-EDM procedures. (b) The classic appearance of such failures. There is a large, remelted surface layer above a reaustenitized, untempered zone
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Published: 01 January 2002
Fig. 20 Dimples in the ductile fracture surface of a permanent mold cast A356 Al-alloy
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Published: 01 January 2002
Fig. 23 Correlation between striation spacing and fatigue life of permanent mold cast modified A356 aluminum alloy specimens tested at 0.5% strain amplitude
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Published: 01 January 2002
Fig. 12 Internal discontinuities in a tire-mold casting. (a) Stringer-type inclusions adjacent to the surface. As-polished. (b) Structure below the surface. Note the change in graphite shape. Unetched. (c) Ferrite matrix with degenerate vermicular graphite nodules. Etched with 2% nital. All
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Image
Published: 01 January 2002
Fig. 30 Permanent mold of 4130 steel for centrifugal casting of gray- and ductile-iron pipe that failed because of localized overheating. The failure was caused by splashing of molten metal at the spigot end. Subsequent overheating resulted in mold-wall spalling and scoring, details of which
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Image
Published: 30 August 2021
Fig. 9 Plastic-mold die made from AISI S7 tool steel that was found to be cracked before use. A crack followed the lower recessed contour of the large gear teeth and had an average depth of 1.6 mm ( 1 16 in.). Smaller cracks were also observed on the flat surfaces. (a) Actual size
More
Image
Published: 30 August 2021
Fig. 19 AISI P20 mold made from prehardened stock that was carburized and rehardened. After heat treatment, it was found to be cracked (arrow). See also Fig. 20 .
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Image
Published: 30 August 2021
Fig. 20 Metallographic section from the AISI P20 mold shown in Fig. 19 . (a) Top part of a macroetched (10% aqueous nitric acid) disk cut from the mold revealing a heavily carburized case. Actual size. (b) Micrograph showing gross carbide buildup at the surface with an underlying region
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