Understanding Mould Wear Mechanisms and Optimising Performance through Nico Coating: An In-Depth Analysis

This research investigates the wear mechanism of moulds and examines the worn areas using high power microscopes and SEM (Scanning Electron Microscopy). In addition, EDS (Energy Dispersive Spectroscopy) and XRF (X-ray fluorescence) techniques are used to compare the worn areas with the normal areas. The results indicate that the wear mechanism of the moulds is similar to adhesive wear. To address the issue of die wear, the application of Nico coating to the copper substrate surface is investigated. Two sample preparation methods, namely DC power supply and dual pulse power supply, are employed. SEM analysis shows that the sample group prepared using the dual pulse power supply has a relatively dense surface coating. The samples with a 60:40 weight ratio of Nico exhibit the highest average hardness and thickness, with minimal dispersion as indicated by the low standard deviation. The samples also show minimal roughness. Repeat tests under the same conditions confirm that the coating surface remains dense and uniform with a hardness of 467.628hv, a thickness of 43.0665um and a roughness of 4.331nm. Nanoindenter test results show that the coating has improved wear resistance (-28.7 gpa) compared to the original mould (-142.4 gpa), an increase of 80%.