1. Die Materials Development Task Force NADCA Headquarters February 11, 2009

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. Tank Tread Heat Sink

5. Trials at St. Clair Die Casting • AM703 • 48- 50 HRC DieVar High Speed Machined • Anvilloy Cores with reduce length to facilitate heat transfer. • Tool has additional cooling line in each of ejector half inserts between cavities. • 0.25” NPT to improve heat removal. • Front and ejector half of die moved 0.375” NPT line from 7/8” to 0.625” below cavity.

6. Trials at St. Clair Die Casting • Currently has 66,507 shots. • Cycle time reduce from 55 sec. to 50 sec. • Can we further reduce with lower oil temp? • Reducing to 230-240°F resulted in poor fill. • Best temperature is about 250°F • Inserts • Slight heat checking in all. • Localized breakout in one insert

7. Premier Tool & Die Cast Co • VacDie 34 (Allvac Ni Base Alloy) • Tilt Steering Column 2 Cavity Die • Cooling Passage 0.120” • Initial Machining Difficulties Settled • VacDie 34 used for slide tips. • PG H13 • 25 K Shots to Crack Initiation • 100 K Shots to Die Retirement • Alloy HT in High Strength Condition

8. Premier Tool & Die Cast Co • Cooling lines at 0.5” instead of 0.75” depth • Cracking Noted at 6K Shots • Allvac evaluation • Material failed due to high temperatures which caused surface reactions with molten Al • Water should be used as coolant instead of hot oil • Allvac believes would not fail if kept cool.