March 30, 2000 Residual Stress Report Page 1 of 15 Die Materials Committee Meeting March 30, 2000 Determine through baseline test measurements the stress Determine through baseline test measurements the stress changes that occur during production cycles. changes that occur during production cycles. Monitor these changes at specific historic area/areas Monitor these changes at specific historic area/areas where upset heat checking first occurs. where upset heat checking first occurs. Phase II - Using this information see what effect Phase II - Using this information see what effect different surface modifications have on this baseline different surface modifications have on this baseline data. data. Knowing this – translate into an economical method to Knowing this – translate into an economical method to measure and predict these changes on site during normal measure and predict these changes on site during normal production processes. production processes. Goals and Objectives – Dynamic
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March 30, 2000 Residual Stress Report
Page 1 of 15Die Materials Committee MeetingMarch 30, 2000
Determine through baseline test measurements the stress Determine through baseline test measurements the stress
changes that occur during production cycles.changes that occur during production cycles.
Monitor these changes at specific historic area/areas where upset Monitor these changes at specific historic area/areas where upset
heat checking first occurs.heat checking first occurs.
Phase II - Using this information see what effect different surface Phase II - Using this information see what effect different surface
modifications have on this baseline data.modifications have on this baseline data.
Knowing this – translate into an economical method to measure Knowing this – translate into an economical method to measure
and predict these changes on site during normal production and predict these changes on site during normal production
processes.processes.
Goals and Objectives – Dynamic
March 30, 2000 Residual Stress Report
Page 2 of 15Die Materials Committee MeetingMarch 30, 2000
Desired die caster criteria for testDesired die caster criteria for testHigh volume runner High volume runner Multiple cavities (4ea preferred)Multiple cavities (4ea preferred)Flat surface prone to h/cFlat surface prone to h/cHistory of rapid h/cHistory of rapid h/cFlexible production schedulingFlexible production schedulingSmaller size inserts for handlingSmaller size inserts for handlingReasonable time frame for resultsReasonable time frame for resultsApproval of end userApproval of end user
Recapping the December 1, 1999 Meeting Notes
March 30, 2000 Residual Stress Report
Page 3 of 15Die Materials Committee MeetingMarch 30, 2000
Bob Ehrman Bob Ehrman AST TechnologiesAST Technologies Jerry SkoffJerry Skoff Badger Metal TechBadger Metal Tech Dr. David SchwamDr. David Schwam Case Western UniversityCase Western University Nanda GopalNanda Gopal Intermet (was Ganton)Intermet (was Ganton) Curt KyonkaCurt Kyonka Pace IndustriesPace Industries Vince AdkarVince Adkar Thyssen SteelThyssen Steel Yeou-Li ChuYeou-Li Chu RyobiRyobi
Committee Assistance Members Arnie FultonArnie Fulton Pace Industries CorpPace Industries Corp Jim BerryJim Berry Pace Industries MOPace Industries MO Roy CecilRoy Cecil Pace Industries MOPace Industries MO Dave ThomasonDave Thomason Pace Industries MOPace Industries MO Rex FishRex Fish GMPTGMPT
Committee Members - via email
- via email
March 30, 2000 Residual Stress Report
Page 4 of 15Die Materials Committee MeetingMarch 30, 2000
high volume runner multiple cavities flat surface prone to h/c history of rapid h/c flexible production schedule smaller size inserts for handling reasonable time frame for results approval of end user
Current Test Site
Pace Industries
March 30, 2000 Residual Stress Report
Page 5 of 15Die Materials Committee MeetingMarch 30, 2000
CASTINGS
GATE FLOW ON CASTINGS
CAVITY #10 CAVITY #9
Biscuitshot
March 30, 2000 Residual Stress Report
Page 6 of 15Die Materials Committee MeetingMarch 30, 2000
Heat check prone area
CAVITY #10
March 30, 2000 Residual Stress Report
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CAVITY #9H
eat c
heck
pro
ne a
rea
March 30, 2000 Residual Stress Report
Page 8 of 15Die Materials Committee MeetingMarch 30, 2000
Cavity #9
Photos taken during Pace visit
ShotBiscuit
Die Sampled350 SHOTS
Approximate area where X-ray and Barkhausen
measurementsare being taken
Directions#1 0 degrees# 2 -45 degrees# 3 -90 degrees
March 30, 2000 Residual Stress Report
Page 9 of 15Die Materials Committee MeetingMarch 30, 2000
Cavity #10
REAR RETAINERPhotos taken during Pace visit
ShotBiscuit
Die Sampled350 SHOTS
Directions#1 0 degrees# 2 -45 degrees# 3 -90 degrees
Approximate area where X-ray and Barkhausen
measurementsare being taken
March 30, 2000 Residual Stress Report
Page 10 of 15Die Materials Committee MeetingMarch 30, 2000
Die was already sampled (350 shots) Die was already sampled (350 shots) (prior to first measurement)(prior to first measurement)
ProcedureProcedureMeasurements taken by AST at specified areas Measurements taken by AST at specified areas
determined by past history and Case Western determined by past history and Case Western recommendationsrecommendations
Die X-ray site plotted for future measurementsDie X-ray site plotted for future measurementsBarkhausen readings in same locationsBarkhausen readings in same locationsInserts returned to Pace for approximately 20-30K Inserts returned to Pace for approximately 20-30K
shotsshotsRepeat measuring cycle for stress and Barkhausen Repeat measuring cycle for stress and Barkhausen
readings until steel upsets & heat checking occursreadings until steel upsets & heat checking occurs
First Measurement
March 30, 2000 Residual Stress Report
Page 11 of 15Die Materials Committee MeetingMarch 30, 2000
Die had 20,523 shots (producing castings (03/29/2000) (Will attempt to pull every 20-30K- takes 2 weeks)
AST commented that, upon receipt, they noted that the calibration area selected on the dies for the 1st measurement appeared to be aggressively ground.
Same reference point used for measurement #1 would make Barkhausen readings (which measures change) not usable.
New calibration piece for reference was made by AST but not from (H-13).
Measurements taken and returned to Pace.
Second Measurement
March 30, 2000 Residual Stress Report
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RESIDUAL STRESS TASK FORCE - REAR RETAINER CAVITY #9 AND CAVITY #10BASELINE TESTING WITHOUT ANY SURFACE TREATMENTS OR COATINGS
Date Shots X-Ray (XRD in KSI) Barkhausen (BNA numerical)Measured 0 degrees -45 degrees -90 degrees 0 degrees -45 degrees -90 degrees
Part Cav #9FIRST READ 02/17/2000 350 +33.3 +/- 2.6 +34.8 +/- 1.8 +41.2 +/- 1.6 80.1 97.6 173.3
SECOND 03/14/2000 20,523 +29.3 +/- 1.8 +38.7 +/- 2.1 +50.7 +/- 1.4 52.9* 54.9* 98.4*
Part Cav #10FIRST READ 02/17/2000 350 +35.7 +/- 1.6 +40.1 +/- E4 +41.0 +/_ 1.2 44.5 81.4 80
SECOND 03/14/2000 20,523 +38.9 +/- 1.8 +59.8 +/- 1.1 +63.9 +/- 1.5 32.4* 64.8* 69*
* The calibration area selected on the dies during run 1 of testing was aggressively ground when the dies .arrived for round #2. A separate calibration piece (not H-13) was created during round 2 that will be kept at AST.
Sensor Units for Barkhausen were same as first time.(Round #2 dies were ground in area where we took reference barkhausen readings)[Barkhausen measures changes - ie: Residual Stresss, Hardness, Micro-structureand outputs it as a numerical value.
March 30, 2000 Residual Stress Report
Page 13 of 15Die Materials Committee MeetingMarch 30, 2000
Measured 0 degrees -45 degrees -90 degrees 0 degrees -45 degrees -90 degreesPart Cav #9FIRST READ 2/17/2000 350 +33.3 +/- 2.6 +34.8 +/- 1.8 +41.2 +/- 1.6 80.1 97.6 173.3
SECOND 3/14/2000 20,523 +29.3 +/- 1.8 +38.7 +/- 2.1 +50.7 +/- 1.4 52.9* 54.9* 98.4*
Part Cav #10FIRST READ 2/17/2000 350 +35.7 +/- 1.6 +40.1 +/- E4 +41.0 +/_ 1.2 44.5 81.4 80
SECOND 3/14/2000 20,523 +38.9 +/- 1.8 +59.8 +/- 1.1 +63.9 +/- 1.5 32.4* 64.8* 69*
* The calibration area selected on the dies during run 1 of testing was aggressively ground when the dies .arrived for round #2. A separate calibration piece (not H-13) was created during round 2 that will be kept at AST.
No trend established as yet, however, indications of
increasing tensile stress developing at measuring point
March 30, 2000 Residual Stress Report
Page 14 of 15Die Materials Committee MeetingMarch 30, 2000
Possible Future Testing:
Ganton Technologies
high volume runner multiple cavities flat surface prone to h/c history of rapid h/c flexible production schedule smaller size inserts for handling reasonable time frame for results approval of end user
March 30, 2000 Residual Stress Report
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Ganton TechnologiesRear Seal
Cover Side
March 30, 2000 Residual Stress Report
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Continue with subsequent X-ray measuring on Continue with subsequent X-ray measuring on Pace diesPace dies
Pursue possibility of working with Ganton Pursue possibility of working with Ganton ((FordFord)) toolingtooling
Next phase - if DOE funding availableNext phase - if DOE funding availableBegin measuring other tooling that has been Begin measuring other tooling that has been
surface treated surface treated Possible studiesPossible studiesMetalifeMetalifeDyna-blue - Ferritic Nitro-CarburizingDyna-blue - Ferritic Nitro-CarburizingMetalife and Dyna-blue in combinationMetalife and Dyna-blue in combinationVarious coatings - i.e.: PVD (Crn, Crc, TiAln) & Various coatings - i.e.: PVD (Crn, Crc, TiAln) &
CVDCVD
Future Studies
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