In the present investigation, a brass
extrusion die of a hinge profile was selected for ameliorating its performance.The original die presented design and material problems,
such as fatigue initiation of cracks and deterioration of its toughness due to aging phenomena. Three new designs, four materials and two
methods of bonding of the insert with the housing were investigated in order to improve the performance of the die. The preliminary
results showed an improvement of about 2.5 times of the original die performance.