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A local company producing aluminum profile encounters frequent failures to bridge dies. In total, 22 dies failed within a year, entailing production disruptions and extensive downtimes. Bridges usually exhibit cracks on the ribs. The failure analysis of the failed parts has been performed in order to propose solution for correct and economical process. The paper aims to discuss these issues.

Recorded history was collected regarding tool’s material selection, manufacturing conditions, usage and service. A representative failed bridge was in depth analyzed. The piece was optically inspected. Rockwell hardness measurements and chemical analysis were performed. The paper is focussed on the microscopic examination of the failed parts. Specimens were cut from bridge’s ribs. Areas including cracks were analyzed on the cross section of the samples by optical and scanning electron microscopy. Local chemical analysis was made by X-ray microanalysis.

Design, deficiency and improper maintenance are considered to be responsible for the systematic die damage. Prolonged preheating duration and poor quality surfaces before nitriding render dies premature unusable. The preheating duration should be controlled and protective atmosphere should be used. Furthermore, it is suggested to protect the ribs during nitriding as a preventive measure against crack initiation. The bridge’s geometry can be improved by fabricating ribs with larger radii. A finer polishing is recommended.

The present analysis resolved a serious deficiency in extrusion production. Extended research has been conducted in the field of aluminum extrusion dies, nevertheless, the present work presents new metallographic aspects as well as some interesting notes regarding the repetitive nitriding of bridge dies.