Method to evaluate the adhesion behavior of aluminum-based alloys on various materials and coatings for lube-free die casting

•A simple and direct method called aluminum adhesion test (AAT) has been developed.•Bare H13 steel and a number of state-of-the-art PVD hard coatings were tested.•Soldering behavior of AAT on bare H13 steel is consistent with literature reports.•At least three hard coatings showed negligible aluminum adhesion.•Casting trial confirmed efficacy of using AAT to predict Al adhesion behavior.

A simple and direct method called the aluminum adhesion test (AAT) has been developed to provide a quantitative assessment of the adhesion strength between an aluminum alloy and both uncoated and coated H13 die steel. Twelve different hard coatings were investigated. The H13 exhibited soldering similar to that observed by previous investigators. At least three coatings exhibited negligible adhesion and one of these, AlCrN, was further investigated because of its excellent oxidation resistance. Actual die-casting trials were conducted using H13 inserts coated with this AlCrN coating and the trial results confirmed the efficacy of using the AAT for predicting non-sticking behavior.

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