Die Materials Die Materials DevelopmentDevelopment Task Force Task Force

NADCA HeadquartersNADCA Headquarters

February 11, 2009February 11, 2009

Areas of InterestAreas of Interest

New die materials to increase die life New die materials to increase die life – Ferrous materialsFerrous materials– Non-ferrous materialsNon-ferrous materials

New die materials to decrease cycle New die materials to decrease cycle time – (i.e. increase productivity) time – (i.e. increase productivity) – High thermal conductivity materials High thermal conductivity materials

GoalGoal

To obtain field information to validate To obtain field information to validate laboratory testing informationlaboratory testing information

To assist in providing information for To assist in providing information for the Specification Task Forcethe Specification Task Force

Tank Tread Heat SinkTank Tread Heat Sink

Trials at St. Clair Die CastingTrials at St. Clair Die Casting

AM703AM703– 48- 50 HRC DieVar High Speed Machined48- 50 HRC DieVar High Speed Machined– Anvilloy Cores with reduce length to Anvilloy Cores with reduce length to

facilitate heat transfer.facilitate heat transfer.– Tool has additional cooling line in each of Tool has additional cooling line in each of

ejector half inserts between cavities.ejector half inserts between cavities. 0.25” NPT to improve heat removal. 0.25” NPT to improve heat removal.

– Front and ejector half of die moved Front and ejector half of die moved 0.375” NPT line from 7/8” to 0.625” below 0.375” NPT line from 7/8” to 0.625” below cavity. cavity.

Trials at St. Clair Die CastingTrials at St. Clair Die Casting

Currently has 66,507 shots.Currently has 66,507 shots. Cycle time reduce from 55 sec. to 50 Cycle time reduce from 55 sec. to 50

sec.sec.– Can we further reduce with lower oil temp?Can we further reduce with lower oil temp?

Reducing to 230-240°F resulted in poor fill.Reducing to 230-240°F resulted in poor fill. Best temperature is about 250°FBest temperature is about 250°F

InsertsInserts– Slight heat checking in all. Slight heat checking in all. – Localized breakout in one insertLocalized breakout in one insert

Premier Tool & Die Cast CoPremier Tool & Die Cast Co

VacDie 34 (Allvac Ni Base Alloy)VacDie 34 (Allvac Ni Base Alloy) Tilt Steering Column 2 Cavity DieTilt Steering Column 2 Cavity Die Cooling Passage 0.120” Cooling Passage 0.120” Initial Machining Difficulties SettledInitial Machining Difficulties Settled VacDie 34 used for slide tips.VacDie 34 used for slide tips. PG H13 PG H13

– 25 K Shots to Crack Initiation25 K Shots to Crack Initiation– 100 K Shots to Die Retirement100 K Shots to Die Retirement

Alloy HT in High Strength ConditionAlloy HT in High Strength Condition

Premier Tool & Die Cast Co Premier Tool & Die Cast Co

Cooling lines at 0.5” instead of 0.75” Cooling lines at 0.5” instead of 0.75” depthdepth

Cracking Noted at 6K ShotsCracking Noted at 6K Shots Allvac evaluationAllvac evaluation

– Material failed due to high temperatures Material failed due to high temperatures which caused surface reactions with which caused surface reactions with molten Almolten Al

– Water should be used as coolant instead Water should be used as coolant instead of hot oilof hot oil

– Allvac believes would not fail if kept cool. Allvac believes would not fail if kept cool.