# A Review of Methods for Increasing the Durability of Hot Forging Tools

## TL;DR

This paper reviews methods to improve the durability of hot forging tools, including material modifications, design changes, and innovative manufacturing techniques.

## Contribution

The paper introduces original design and technological solutions for forging dies, including a zonal hardfacing approach and computer simulations for wear prediction.

## Key findings

- An innovative concept for manufacturing forging dies from alloy structural steels with welded impressions is proposed.
- A zonal hardfacing approach is introduced, using welds with different chemical compositions based on wear mechanisms.
- Computer simulations are emphasized for predicting wear and optimizing tool geometry.

## Abstract

The article presents a comprehensive review of key issues and challenges related to enhancing the durability of hot forging tools. It discusses modern strategies aimed at increasing tool life, including modifications to tool materials, heat treatment, surface engineering, tool and die design, die geometry, tribological conditions, and lubrication. The review is based on extensive literature data, including recent publications and the authors’ own research, which has been implemented under industrial conditions at the modern forging facility in Forge Plant “Glinik” (Poland). The study introduces original design and technological solutions, such as an innovative concept for manufacturing forging dies from alloy structural steels with welded impressions, replacing traditional hot-work tool steel dies. It also proposes a zonal hardfacing approach, which involves applying welds with different chemical compositions to specific surface zones of the die impressions, selected according to the dominant wear mechanisms in each zone. General guidelines for selecting hardfacing material compositions are also provided. Additionally, the article presents technological processes for die production and regeneration. The importance and application of computer simulations of forging processes are emphasized, particularly in predicting wear mechanisms and intensity, as well as in optimizing tool and forging geometry.