MAXXSHOT & MAXXSHOT PLUS ARE

PROVEN SURFACE TREATMENTS FOR

NEW & USED DIE CAST TOOLING
“TO PROLONG HEAT CHECK, SOLDERING & EROSION”

PROLONG SURFACE TECHNIKS

PLOT NO: C24, SHED NO: 2 SIDCO
PHASE 1 & 2, SIPCOT 1, HOSUR – 635 126
CONTACT NO: - +91 7539925014
Mail: service@prolongindia.com
Website: www.prolongindia.com
Introduction

Prolong Surface Techniks is a solution oriented firm focused on thermal & surface
engineering technology. Our technical expertise in tooling & applications helps to understand the
customer need of increasing the Tool performance through various processes.
Currently Prolong Surface is offering services like Stress tempering; Magnetite & MaxxShot
process to support Die casting industry and will continue to expand the facility with various surface
treatment technologies.

Stress Tempering
Stress Tempering is a process to reduce or eliminate
the tensile stresses present on the surface of a die after it
has been in production for a period of time, thereby
enhancing die life. This process is also commonly referred
to as stress relieving throughout the industry.

Recommended cases for Stress tempering:

 After any EDM work (mandatory).

 After final machining (mandatory).
 After weld repair of a finished die (mandatory).
 Prior to weld repair of a finished die (desired).
 After the die has been in service for a predetermined number of shots (mandatory).
Stress tempering should be performed on die casting dies after the initial die sampling and
then on a scheduled basis, depending on the severity of heat checking experienced.
Generally, it is recommended that stress tempering be performed after the running-in
period of the die and then after 1000-2000 and 5,000-10,000 shots. The procedure is then
repeated for each additional 10,000-20,000 shots, so long as the die exhibits only minor amounts
of heat checking.

Magnetite
Magnetite is an advanced oxidation process which produces thin oxide layer (Fe3o4) on
the surface of the die. In Die Casting process, this oxide layer acts as a barrier between the Die
steel and liquid Aluminum. Also this oxide layer helps to retain the lubricant (Die coat) on the die
surface. Magnetite layer also provides better protection from Soldering.

Benefits from Prolong Surface Techniks:

 Reducing tensile stress
 Prolonged Heat check initiation
 Reducing the downtime
 Prolonging the preventive maintenance
 Increased Corrosion Resistance
 Improved Wear Resistance
 Prolonging Soldering effect
 Easier component ejection
MaxxShot
Maxxshot is a specialized surface treatment process to induce compressive residual stress
on the surface & sub surface, thereby increasing the Heat Check Resistance, avoiding Pitting
Corrosion & Stress Corrosion Cracking (SCC).

Heat Checking is a tensile stress fatigue which is influenced by following factors:

 Hardness, Toughness & Hot yield strength of Tool Steel

 Residual Tensile Stress induced due to hard machining
 Surface deterioration due to machining challenges
 EDM surface defects
 Inadequate Die maintenance
 Casting process parameter

MaxxShot is a highly controlled bombardment process which creates a reactive action from the
material core thus resulting in a beneficial surface & sub surface compressive residual stress.

MaxxShot process includes Stress tempering, Removing EDM layer & Correcting Surface
deterioration, Inducing Compressive Stress & Magnetite Coating.

MaxxShot Plus
MaxxShot Plus is a Duplex process in which, MaxxShot is carried out in combination
with a superior controlled Nitriding process (Tufftride) followed by secondary surface
preparation and Magnetite.

MaxxShot Plus with higher Nitriding case depth increases the life of press forging dies
significantly.

SEM Image of Magnetite Layer SEM image of Magnetite

(Flower Petal like structure - Fe3o4)
 Residual Stress
Sample Processes
(Avg.) (Mpa)
MaxxShot without
-784
Magnetite Layer
MaxxShot -550
Only Magnetite -634
Ball Milled
113
(Untreated/30 deg)

Sample Processes Hardness in Hv

End Mill
659.3
(Untreated)
MaxxShot 802.6 Surface Defects due to Hard Machining:-
Ball Milled Micro Cracks, Surface Rupture, Plastic
557 Deformation & Detrimental Strain Hardening
(Untreated)

Processed Dies:-
Before Process After Process Before Process After Process

Before Process After Process Before Process After Process

Our Customers

PROLONG SURFACE TECHNIKS

PLOT NO: C24, SHED NO: 2 SIDCO, PHASE 1 & 2,
SIPCOT 1, HOSUR – 635 126, CONTACT NO: - +91 7539925014
Mail: service@prolongindia.com, Web: www.prolongindia.com