Metallife and Thermallife and othe pvd coatings to extend die casting die life and improving performance of die casting dies and other molds.

Although coatings prove beneficial to improving tool life, many PVD coatings are deposited in a columnar fashion leaving clear paths to the substrate material. It is recommended that proper substrate preparation include a compressive layer. MetaLL ifeÒ accomplishes this and at the same time removes grain boundary inclusions that affect the coating’s integrity. Fatigue deficits may also occur if there is micro-cracking in the coating’s brittle surface.

Under fatigue loading, the micro-cracks in the coating can propagate into the base metal and lead to fatigue failure. When the base metal is MetaLL ifeÒ processed, the potential for fatigue crack propagation into the base metal from the plating is dramatically reduced. The graphic (Figure 9) depicts micro-cracking propagating into the base material. After processing, the graphic (Figure 9a) shows the MetaLL ifeÒ compressive layer preventing the micro-cracking from propagating into the base material. MetaLL ifeÒ prior to coating is recommended on cyclically loaded parts to enhance fatigue properties.

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