Die Materials Development Task Force Update

Die Materials Die Materials DevelopmentDevelopment Task Force Task Force

UpdateUpdateNADCANADCA

February 21, 2007February 21, 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. ClairTrials at St. Clair Die Casting Die Casting

HubHub Four cavity dieFour cavity die One Dievar one Marcast insertOne Dievar one Marcast insert Two FNC PG H13 insertsTwo FNC PG H13 inserts 332,000 shots, Out of Service 332,000 shots, Out of Service

7/1/05 7/1/05 – Dievar looks best – slight washout, Dievar looks best – slight washout,

minimal heat check at ejector pinsminimal heat check at ejector pins– Marcast more checking than H13 Marcast more checking than H13

Goal 250,000-300,000 shotsGoal 250,000-300,000 shots

The Cast PartThe Cast Part

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

Tank Tread Heat SinkTank Tread Heat Sink Four Cavity DieFour Cavity Die One Dievar & One QRO-90 Insert, AM703One Dievar & One QRO-90 Insert, AM703 181,000 Shots, Removed from service May, 2004181,000 Shots, Removed from service May, 2004

– 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 H13QRO-90 welded 5 times, break-out, but better than H13 37 HRC lowest37 HRC lowest

Dievar Die (AM596) – 174,000 Shots Heat checks Dievar Die (AM596) – 174,000 Shots Heat checks at ejectors and front half required regular repair. at ejectors and front half required regular repair. Taken out of service 12/13/04Taken out of service 12/13/04

Tank Tread Heat SinkTank Tread Heat Sink

Tank Tread Heat SinkTank Tread Heat Sink

Trials at St. Clair Die CastingTrials at St. Clair Die Casting Pre-hardened Dievar insert w/ 181K shot Pre-hardened Dievar insert w/ 181K shot

Dievar insert, AM703Dievar insert, AM703– 42- 43 HRC, pre-hardened Dievar42- 43 HRC, pre-hardened Dievar– Sanding of breakouts required after 19K shots.Sanding of breakouts required after 19K shots.– Pulled after 47,000 shots on pre-hardened Pulled after 47,000 shots on pre-hardened

Dievar, 220K shots on conventional DievarDievar, 220K shots on conventional Dievar High speed machined Dievar, AM080High 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, same breakout, some light heat 122,000 shots, same breakout, some light heat

checking (June ’06)checking (June ’06)– Now 161,00 shots, (Feb. 07) breakout slightly Now 161,00 shots, (Feb. 07) breakout slightly

increasing, still acceptable.increasing, still acceptable.

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

Allvac Nickel AlloysAllvac Nickel Alloys68°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

VacDie 34 Field TrialVacDie 34 Field Trial Allvac willing to put money in.Allvac willing to put money in. Allvac to be involved in die design.Allvac to be involved in die design. Run die to failure.Run die to failure. Erosion/washout unknown.Erosion/washout unknown. Sample sent to CWRU for further studySample sent to CWRU for further study

– To settle internal debate on whether To settle internal debate on whether cracking seen in thermal fatigue tester cracking seen in thermal fatigue tester was due to corrosion fatigue from steam was due to corrosion fatigue from steam generated during quenchgenerated during quench

VacDie 34 Field TrialVacDie 34 Field Trial Trials Being Planned at St. Clair and Trials Being Planned at St. Clair and

Premier Die CastingPremier Die Casting Moved from 300 lb, 8” diam Lab Moved from 300 lb, 8” diam Lab

HeatsHeats Now have 8,500 lb, 20” diam heat Now have 8,500 lb, 20” diam heat

pressed forged to 13” diam pressed forged to 13” diam Two Pieces Sent to PremierTwo Pieces Sent to Premier

Other FutureOther Future Bohler W360 ISO BlocBohler W360 ISO Bloc

– Lower Si, Higher MoLower Si, Higher Mo– Capable of 58 HRCCapable of 58 HRC– Good toughness for hardness levelGood toughness for hardness level– Commercially availableCommercially available

Bohler W400 VMRBohler W400 VMR– When cracking is a major issueWhen cracking is a major issue– 50-52 HRC50-52 HRC