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4 Success Stories T09-074

4 Success Stories T09-074. Jerald (Jerry) V. Skoff - Founder Badger Metal Tech, Inc. Benefits of Compressive Stress Surface Engineering. Fill Problem - FiveStar. Case C0987 MN – 2008 – Bake Pan FiveStar Blistering in cosmetic area of brownie pan Teflon coating adhesion problem

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4 Success Stories T09-074

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  1. 4 Success Stories T09-074 • Jerald (Jerry) V. Skoff - Founder • Badger Metal Tech, Inc. • Benefits of Compressive Stress • Surface Engineering North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  2. Fill Problem - FiveStar • Case C0987 MN – 2008 – Bake Pan • FiveStar • Blistering in cosmetic area of brownie pan • Teflon coating adhesion problem • 40 parts scrapped in 10 hour shift North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  3. Solution to Fill - FiveStar • FiveStarCompressive Stress processing • T41 – 5-6C Almen – 460 media • 10A - .011 • 3A – GB • Cover and Ejector plus Gate North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  4. FiveStar - Photo North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  5. Five Star - ROI Benefits • FiveStar • Laminar fill disappeared • Blistering stopped • Metal flow improved • Scrap dropped from 40 to 2 castings/10 hr shift95% reduction North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  6. Heat Checking Problem - Kirby • Case C0082 TX – 2008 – Vacuum Cleaner • Kirby • Non cosmetic • & • Cosmetic • 6-7 components • 30-35K Heat check would start on new tooling North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  7. Solution to Heat Checking - Kirby • KirbyCompressive Stress processing • T41 – 5-6C Almen – 460 media • 10A - .011 • 3A – GB • Entire cast area of cosmetic side/sides • New tooling with polished castings North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  8. Kirby - Photos North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  9. ROI Benefits - Kirby • Kirby • No heat checking until 93K shots • 3x 200% increase (30-35K before) • Better castings, easier to polish • No hidden porosity or inclusions • Begin doing on all dies including • auto finish high buff castings North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  10. Shortened tool life problem - Toro • Case C0266 – MN – Mower Decks • Toro • Thick wall castings – 150K life • Gate velocity 120-130 ft/sec • Good SPC North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  11. Toro - Photos North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  12. Solution to short tool life - Toro • ToroCompressive Stress Processing • T40H – 8-9C Almen – 460 media • 4A – GB • Entire cast areas – cosmetic • Also some inserts that soldered received • PM program every season • In place for 18 years North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  13. ROI Benefits - Toro • Toro • Reduced casting defects • Less die welding • Scrap rate reduction • Improved flow • Paint adhesion • Large return on investmentfrom 150K to increase of 370K+ (+146%) North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  14. Find effective PM program - Lamar • AluminumC0670 – CA Lamar Die Casting • Vendo – vending machine parts • Before 180K for Vendo Gauge Bar & Gate • 380 aluminum • Bronwite - Brass • Weather-Tec – impact sprinkler heads • Before 100,000 parts (8 cav) Weathertec • (1550 [1625] degree F Bronwite metal)CC99750 (brass 60% Cu, 20% Mn) North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  15. Lamar - Photo North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  16. Solution to PM Search - Lamar • Lamar • Vendo Gauge Bar & Gate - (75K, every 100K) • High Production – 520K/yr • 180K to 420K Avg each die (+133%) • Weather-Tec Sprinkler Head • High production • From 100K to 200K+ – Still producing parts North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  17. More Case Studies 1986-2009 www.badgermetal.com/field-ml.htm • Breakout & Pitting from cavitation effect • C0027, C0258, C0376, C0834, C0542, etc. • Heat Checking – C0001, C0870, C0753, C0321 • Soldering – C0704, C0670, C0481 • Porosity - C0274, C0693, C0150 • Flow Problems – C0031, C0025, C0609 • Laminar Fill – C0274, C0310 www.badgermetal.com/field-tl.htm North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

  18. Case Studies North American Die Casting Association – 113th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA

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