A previous examination of spark-eroded surfaces in industrial operation has enabled some relevant factors to be studied in the laboratory. The endurance limit of hot-worked die steels at working temperature has been found to correlate with die life when fracture is the controlling failure mechanism. Also, metallurgical examination shows that the endurance limit is related to the microstructural features. The use of electrical-discharge machining (EDM) has a significant effect on the endurance limit. A mechanism of oxidation-aided wear has been considered for dies which wear out-of-tolerance. The possible wear of the EDM surface by plucking has been examined.
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