Performance of Hybrid Forging Dies: Unveiling the Role of Hardfaced Coatings in Stress Distribution and Wear Resistance

This paper presents an innovative approach to increasing the service life of hot forging dies by substituting standard hot-work tool steels (55NiCrMoV7) with heat-treatable structural steel (42CrMo4) reinforced via hardfacing. The study investigates the regeneration process using specific hardfacing wires (UTOP38, F-812, F-818) to create surface layers resistant to wear, thermal fatigue, and plastic deformation. The proposed technology was validated under industrial conditions, demonstrating a significant durability increase of approximately 109% compared to conventional monolithic dies. Metallographic analysis revealed beneficial hardness gradients and distinct microstructural characteristics of the welded layers. An explicit FEM analysis demonstrated that extreme contact stresses are strictly confined to the hardfaced layer. This protects the structural steel core, ensuring macroscopic stability and preventing plastic yielding under forging loads.