Towards the designer surface for ceramic injection moulds

Zhou, Jun (2014). Towards the designer surface for ceramic injection moulds. University of Birmingham. M.Phil.

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Abstract

The ceramic injection moulds used by Doncasters are made of P20 steel and coated with a TiAlN layer. Nevertheless, the rejection rates of the products follow a high-low-high pattern. In this project, the mould at Doncasters was inspected twice in order to study its damage process and the mechanism involved. Six surface systems on P20 tool steel were designed and compared, namely single systems TiAlN (TiAlN coating), DiC (Dymon-iC coating) and GiC (Graphit-iC coating), and duplex systems PNTiAlN, PNDiC and PNGiC (i.e. TiAlN, DiC and GiC coatings on plasma nitrided P20 respectively). The inspection of the ceramic injection mould used by Doncasters reveals that the size and number of pits/craters and the extent of coating delamination increase with service time. The experimental results reveal that the new duplex PNDiC and PNGiC systems are expected to be the desirable surface systems for high-performance and long-life ceramic injection moulds due to their smooth surface, low-friction, high load bearing capacity, high H/E ratio and hence good wear resistance.

Type of Work:

Thesis (Masters by Research > M.Phil.)

Award Type:

Masters by Research > M.Phil.

Supervisor(s):