Identifying the dominant failure mode in the hot extrusion tooling used to forge nickel based superalloy

Magnus Anderson, Kenny McGuire, Remi Christophe Zante, William Ion, Andrzej Rosochowski, Jeffery Brooks

Research output: Contribution to journalArticlepeer-review

15 Citations (Scopus)


The dies used in the extrusion of nickel based super alloys are subject to severe mechanical and thermal stresses, resulting in shortened life and high manufacturing costs. It is necessary to understand the dominant damage mode in order to guide improvements for increased tool life. The operation under examination consists of the hot extrusion of a nickel based superalloy using nitrided hot work tool steel, glassed workpieces and graphite lubrication. The investigation was conducted through a combination of metallurgical analysis, metrology and finite element analysis. Out of the damage modes observed under these conditions, the plastic deformation of the substrate was found to be the cause for tool failure. This paper discusses the relationship between plastic deformation of the substrate and the formation of scoring marks, which fail the die.
Original languageEnglish
Pages (from-to)111–119
Number of pages9
JournalJournal of Materials Processing Technology
Issue number1
Publication statusPublished - Jan 2013


  • die life
  • nitrided hot work tool steel
  • failure analysis
  • failure modes
  • dominant failure mode
  • hot extrusion tooling
  • nickel based superalloy


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