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Die Materials Development Task Force Update

This report discusses advancements in die materials aimed at increasing die life and reducing cycle times in die casting processes. It highlights the performance and durability of various materials, including ferrous and non-ferrous alloys, and presents findings from trials conducted at the St. Clair Die Casting Hub. Notable materials like Dievar and AM703 show promising results for achieving high shot counts with minimal degradation. The goal is to provide actionable data to inform the Specification Task Force Trials and optimize production efficiencies in die casting operations.

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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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