Die Materials Die Materials DevelopmentDevelopment Task Force Task Force

Oak Ridge National LaboratoryOak Ridge National Laboratory

June 13, 2007June 13, 2007

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 materialsHigh 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

Trials at Die CasterTrials at Die Caster

Need multi-cavity die or single die Need multi-cavity die or single die with documented history. with documented history.

Need to log information for Need to log information for appropriate record keeping on form appropriate record keeping on form that was developedthat was developed

Trials at St. Clair Die Trials at St. Clair Die CastingCasting

Tank Tread Heat SinkTank Tread Heat Sink Four Cavity DieFour Cavity Die 181,000 Shots, Removed in 5/20/04181,000 Shots, Removed in 5/20/04

– Dievar looks best, slight heat checks (5x life of H13)Dievar looks best, slight heat checks (5x life of H13) 41HRC lowest 41HRC lowest Placed back in AM703, run to 220,000 shots Placed back in AM703, run to 220,000 shots

– QRO-90 welded 5 times, break-out, but better than QRO-90 welded 5 times, break-out, but better than H13H13 37 HRC lowest37 HRC lowest

New Dievar Die (AM596) – 173,510 Shots New Dievar Die (AM596) – 173,510 Shots Removed 12/12/04 Minimal heat checks at Removed 12/12/04 Minimal heat checks at ejectorsejectors

Pre-Hardened Dievar Die (AM703) – 47,000 shotsPre-Hardened Dievar Die (AM703) – 47,000 shots– 42-43 HRC42-43 HRC– Break-outs and sharp edgesBreak-outs and sharp edges– Pulled when AM080 was placed in servicePulled when AM080 was placed in service

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

High Speed Machined Dievar (AM080)High Speed Machined Dievar (AM080)– 48- 49 HRC48- 49 HRC– 66,000 shots before breakout66,000 shots before breakout– 95,000 shots, breakout no worse95,000 shots, breakout no worse– 122,000 shots, some breakout, some light 122,000 shots, some breakout, some light

heat checking.heat checking.– 161,000 shots, some breakout, soon will 161,000 shots, some breakout, soon will

violate flatness callout.violate flatness callout.– 168,000 shots, no changes.168,000 shots, no changes.– 174,872 shots, no appreciable change.174,872 shots, no appreciable change.

Tank Tread Heat SinkTank Tread Heat Sink

Allvac Nickel AlloysAllvac Nickel Alloys

68°F 1000°F Alloy H.T. UTS YS EL RA Charpy UTS YS EL RA

FH* 202.5 136.8 29.0 54.7 71.0 174.1 123.0 26.1 55.5 VACDIE 34

HT 201.6 131.5 26.4 55.0 63.0 183.1 118.6 21.0 49.3

FH 221.4 154.0 24.1 41.6 61.5 197.9 145.0 21.4 42.0 WM44

HT 217.5 148.5 23.6 42.3 49.5 201.3 139.9 16.8 32.9

FH 207.5 146.3 29.2 55.5 89.0 173.5 128.2 27.0 56.0 WM46

HT 207.2 141.1 24.2 43.7 54.0 185.4 126.5 20.3 47.0

Allvac Nickel AlloysAllvac Nickel Alloys

Tested numerous alloysTested numerous alloys Found that nickel alloys were Found that nickel alloys were

cracking by corrosion fatigue, not cracking by corrosion fatigue, not thermal fatigue.thermal fatigue.

VacDie 34VacDie 34– Heat treatment makes differenceHeat treatment makes difference– TMP is importantTMP is important– Ready for in-plant trialsReady for in-plant trials

VacDie 34VacDie 34

Trial at Premier Tool & Die Cast Corp.Trial at Premier Tool & Die Cast Corp.– Two cavity die – steering column tilt Two cavity die – steering column tilt

housinghousing– 25,000 crack initiation25,000 crack initiation– 100,000 shots for replacement100,000 shots for replacement

Premier has materialPremier has material– Got past machining problemsGot past machining problems– Allvac provided parametersAllvac provided parameters– Die rough machined and heat treatedDie rough machined and heat treated– In final machiningIn final machining