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Die Materials Development Task Force Update

Die Materials Development Task Force Update. NADCA February 21, 2007. Areas of Interest. New die materials to increase die life Ferrous materials Non-ferrous materials New die materials to decrease cycle time – (i.e. increase productivity)

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Die Materials Development Task Force Update

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  1. Die Materials Development Task ForceUpdate NADCA February 21, 2007

  2. Areas of Interest • New die materials to increase die life • Ferrous materials • Non-ferrous materials • New die materials to decrease cycle time – (i.e. increase productivity) • High thermal conductivity materials

  3. Goal • To obtain field information to validate laboratory testing information • To assist in providing information for the Specification Task Force

  4. Trials at Die Caster • Need multi-cavity die or single die with documented history. • Need to log information for appropriate record keeping on form that was developed

  5. Trials at St. Clair Die Casting Hub • Four cavity die • One Dievar one Marcast insert • Two FNC PG H13 inserts • 332,000 shots, Out of Service 7/1/05 • Dievar looks best – slight washout, minimal heat check at ejector pins • Marcast more checking than H13 • Goal 250,000-300,000 shots

  6. The Cast Part

  7. Trials at St. Clair Die Casting Tank Tread Heat Sink • Four Cavity Die • One Dievar & One QRO-90 Insert, AM703 • 181,000 Shots, Removed from service May, 2004 • Dievar looks best, slight heat checks (5x life of H13) • 41HRC lowest • Placed back in AM703, run to 220,000 shots • QRO-90 welded 5 times, break-out, but better than H13 • 37 HRC lowest • Dievar Die (AM596) – 174,000 Shots Heat checks at ejectors and front half required regular repair. Taken out of service 12/13/04

  8. Tank Tread Heat Sink

  9. Tank Tread Heat Sink

  10. Trials at St. Clair Die Casting • Pre-hardened Dievar insert w/ 181K shot Dievar insert, AM703 • 42- 43 HRC, pre-hardened Dievar • Sanding of breakouts required after 19K shots. • Pulled after 47,000 shots on pre-hardened Dievar, 220K shots on conventional Dievar • High speed machined Dievar, AM080 • 48- 49 HRC • 66,000 shots before breakout • 95,000 shots, breakout no worse • 122,000 shots, same breakout, some light heat checking (June ’06) • Now 161,00 shots, (Feb. 07) breakout slightly increasing, still acceptable.

  11. Allvac Nickel Alloys • Tested numerous alloys • Found that nickel alloys were cracking by corrosion fatigue, not thermal fatigue. • VacDie 34 • Heat treatment makes difference • TMP is important

  12. Allvac Nickel Alloys

  13. VacDie 34 Field Trial • Allvac willing to put money in. • Allvac to be involved in die design. • Run die to failure. • Erosion/washout unknown. • Sample sent to CWRU for further study • To settle internal debate on whether cracking seen in thermal fatigue tester was due to corrosion fatigue from steam generated during quench

  14. VacDie 34 Field Trial • Trials Being Planned at St. Clair and Premier Die Casting • Moved from 300 lb, 8” diam Lab Heats • Now have 8,500 lb, 20” diam heat pressed forged to 13” diam • Two Pieces Sent to Premier

  15. Other Future • Bohler W360 ISO Bloc • Lower Si, Higher Mo • Capable of 58 HRC • Good toughness for hardness level • Commercially available • Bohler W400 VMR • When cracking is a major issue • 50-52 HRC

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