North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

4 Success Stories T09-074Jerald (Jerry) V. Skoff - Founder

Badger Metal Tech, Inc.

Benefits of Compressive Stress

Surface Engineering

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

Fill Problem - FiveStar

Case C0987 MN – 2008 – Bake PanFiveStar

Blistering in cosmetic area of brownie panTeflon coating adhesion problem40 parts scrapped in 10 hour shift

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

Solution to Fill - FiveStarFiveStar

Compressive Stress processingT41 – 5-6C Almen – 460 media

10A - .0113A – GB

Cover and Ejector plus Gate

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

FiveStar - Photo

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

Five Star - ROI BenefitsFiveStar

Laminar fill disappearedBlistering stopped

Metal flow improved

Scrap dropped from 40 to 2 castings/10 hr shift

95% reduction

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

Heat Checking Problem - KirbyCase C0082 TX – 2008 – Vacuum Cleaner

KirbyNon cosmetic

&Cosmetic

6-7 components30-35K Heat check would start on new

tooling

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

Solution to Heat Checking - KirbyKirby

Compressive Stress processingT41 – 5-6C Almen – 460 media

10A - .0113A – GB

Entire cast area of cosmetic side/sides

New tooling with polished castings

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

Kirby - Photos

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

ROI Benefits - KirbyKirby

No heat checking until 93K shots3x 200% increase (30-35K before)Better castings, easier to polishNo hidden porosity or inclusions

Begin doing on all dies includingauto finish high buff castings

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

Shortened tool life problem - ToroCase C0266 – MN – Mower Decks

ToroThick wall castings – 150K life

Gate velocity 120-130 ft/secGood SPC

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

Toro - Photos

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

ToroCompressive Stress Processing

T40H – 8-9C Almen – 460 media4A – GB

Entire cast areas – cosmeticAlso some inserts that soldered received

PM program every seasonIn place for 18 years

Solution to short tool life - Toro

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

ROI Benefits - ToroToro

Reduced casting defectsLess die welding

Scrap rate reductionImproved flowPaint adhesion

Large return on investmentfrom 150K to increase of 370K+ (+146%)

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

Find effective PM program - LamarAluminum

C0670 – CA Lamar Die CastingVendo – vending machine parts

Before 180K for Vendo Gauge Bar & Gate380 aluminum

Bronwite - BrassWeather-Tec – impact sprinkler heads

Before 100,000 parts (8 cav) Weathertec(1550 [1625] degree F Bronwite metal)

CC99750 (brass 60% Cu, 20% Mn)

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

Lamar - Photo

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

Solution to PM Search - LamarLamar

Vendo Gauge Bar & Gate - (75K, every 100K)High Production – 520K/yr

180K to 420K Avg each die (+133%)

Weather-Tec Sprinkler HeadHigh production

From 100K to 200K+ – Still producing parts

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

More Case Studies 1986-2009

• Breakout & Pitting from cavitation effect C0027, C0258, C0376, C0834, C0542, etc.• Heat Checking – C0001, C0870, C0753, C0321 • Soldering – C0704, C0670, C0481• Porosity - C0274, C0693, C0150• Flow Problems – C0031, C0025, C0609• Laminar Fill – C0274, C0310

www.badgermetal.com/field-ml.htmwww.badgermetal.com/field-tl.htm

North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA

AFS NADCA

Case Studies