Coating Application Case Studies
Real-world electro-spark deposition coating applications, documented from TechnoCoat's own production history on aluminum die casting dies and forming dies. These are not illustrative examples — each case below records the actual work piece, base metal, and electrode used in the field, so the results are concrete and verifiable rather than generic marketing claims.
The wear, erosion and scuffing resistance seen in these cases comes from the same low-heat-input electro-spark mechanism described on the Electro-Spark Deposition Overview page: a hard carbide electrode (WC, TiC, or similar) is metallurgically bonded to the die surface, spark by spark, without the distortion risk of welding.
Aluminum die casting die — erosion & scuffing prevention
Before
After
Aluminum die casting die is subject to encroachment and erosion by molten metal attacks. Coating with tungsten carbide or particular Cermet electrodes provides a layer with harder high-temperature hardness that is less reactive with molten metal. As a result, dies are protected from erosion, scuffing, and heat-cracks, and given longer lives — while also improving release properties, liquid flow, and gas release, as well as product quality.
| Work Piece | Aluminum die casting die |
|---|---|
| Objective | Prevent erosion and scuffing |
| Process | Coating |
| Base metal | H13 (SKD-61) |
| Electrode | Tungsten carbide |
Automotive engine die — gate protection
Before
After
Coating work on the whole part of an aluminum die casting die for automotive engines. Achieves increased service life due to its extremely high anti-wetting property against molten metal, scuffing resistance, and wearing resistance.
| Work Piece | Aluminum die casting die for automotive engine |
|---|---|
| Objective | Protect the gate area from erosion and scuffing |
| Process | Coating |
| Base metal | H13 (SKD-61) |
| Electrode | Tungsten carbide |
Automotive wheel low-pressure casting die
Before
After
Coating on the low-pressure casting die of an automotive aluminum wheel achieves better liquid flow, gas release, and adhesion of release agents, while preventing erosion, scuffing, and heat cracks.
| Work Piece | Low-pressure casting die of automotive aluminum wheel |
|---|---|
| Objective | Die maintenance |
| Process | Coating |
| Base metal | 4130 (SCM) |
| Electrode | Cobalt molybdenum alloy |
Tube forming die — grip action
Before
After
Tube forming dies lose their grip action as their surfaces wear. A rough coating with tungsten carbide restores better grip action.
| Work Piece | Tube forming die |
|---|---|
| Objective | Better grip action |
| Process | Coating |
| Base metal | W1 (SK) |
| Electrode | Tungsten carbide |
See the overlay repair application case studies, or return to the Electro-Spark Deposition Overview and Resources index.