Abstract: A die casting apparatus for manufacturing metal parts for automotive vehicle applications is provided. The die casting apparatus includes upper and lower dies presenting forming surfaces and a mold cavity therebetween. A replaceable insert and sub-inserts provide portions of the forming surfaces of the dies in areas most prone to wear and erosion. The replaceable inserts and sub-inserts can be removed and replaced during high volume production, without having to replace the entire die. A wear and/or heat resistant coating can be applied to the inserts and sub-inserts to further increase service life. A plurality of cooling channels can also be formed in the inserts and sub-inserts to improve cycle time and quality of the parts.

Abstract: A die casting apparatus for manufacturing metal parts for automotive vehicle applications is provided. The die casting apparatus includes upper and lower dies presenting forming surfaces and a mold cavity therebetween. A replaceable insert and sub-inserts provide portions of the forming surfaces of the dies in areas most prone to wear and erosion. The replaceable inserts and sub-inserts can be removed and replaced during high volume production, without having to replace the entire die. A wear and/or heat resistant coating can be applied to the inserts and sub-inserts to further increase service life. A plurality of cooling channels can also be formed in the inserts and sub-inserts to improve cycle time and quality of the parts.