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Die Materials Development Task Force

Die Materials Development Task Force. Oak Ridge National Laboratory June 13, 2007. 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)

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Die Materials Development Task Force

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  1. Die Materials Development Task Force Oak Ridge National Laboratory June 13, 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 Tank Tread Heat Sink • Four Cavity Die • 181,000 Shots, Removed in 5/20/04 • 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 • New Dievar Die (AM596) – 173,510 Shots Removed 12/12/04 Minimal heat checks at ejectors • Pre-Hardened Dievar Die (AM703) – 47,000 shots • 42-43 HRC • Break-outs and sharp edges • Pulled when AM080 was placed in service

  6. Trials at St. Clair Die Casting • High Speed Machined Dievar (AM080) • 48- 49 HRC • 66,000 shots before breakout • 95,000 shots, breakout no worse • 122,000 shots, some breakout, some light heat checking. • 161,000 shots, some breakout, soon will violate flatness callout. • 168,000 shots, no changes. • 174,872 shots, no appreciable change.

  7. Tank Tread Heat Sink

  8. Allvac Nickel Alloys

  9. 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 • Ready for in-plant trials

  10. VacDie 34 • Trial at Premier Tool & Die Cast Corp. • Two cavity die – steering column tilt housing • 25,000 crack initiation • 100,000 shots for replacement • Premier has material • Got past machining problems • Allvac provided parameters • Die rough machined and heat treated • In final machining

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