Böhler W360 ISOBLOC is well known as high performance hot work tool steel. The main characteristics are high thermal and wear stability, hardness in use up to 57 HRC and particularly the resistance against crack propagation. Therefore the main applications are as thermal and mechanical highly stressed tools among others for Al high pressure die casting (HPDC) inserts.
Nowadays the Laser Powder Bed Fusion (L-PBF) technology enables the production of tools with conformal cooling for e.g. aluminum HPDC. However, only few additive manufacturing powder (AMPO) alloys for additive manufacturing of dies and inserts are commercial available. Due to its easy printability, 18% Ni maraging steel (1.2709, Maraging 300 ≈ Böhler W722 AMPO) is mostly used for inserts with conformal cooling. Nevertheless, this type of alloy is originally not designed for applications in aluminum HPDC. Here, the Böhler W360 AMPO combines the material suitability of W360 ISOBLOC for pressure die casting with the advantages of additive manufacturing.
However, the resistance against dissolution in Al-melt (soldering) as well as thermal fatigue determines the performance of aluminum high-pressure die casting tool materials. In order to rate the performance, two specifically designed test setups that simulate the occurring stress under harsh conditions are developed. These are the immersion stirring- and the thermal fatigue tests. Furthermore, the performance of the commonly hot work tool steel Böhler W300 ISOBLOC (H11, 1.2343) is used as a zero respectively baseline for assessment of the investigated materials, because it is “state of the art” for HPDC.
In this study the performance of Böhler W360 ISOBLOC as well as W360 AMPO according to the thermochemical and thermal fatigue resistance is compared. Additionally, the Böhler W722 AMPO is considered in the comparison in order to determine its suitability for HPDC. The results will be discussed in this presentation.