Goals and Objectives – Dynamic

1. Determine through baseline test measurements the stress changes that occur during production cycles. Monitor these changes at specific historic area/areas where upset heat checking first occurs. Phase II - Using this information see what effect different surface modifications have on this baseline data. Knowing this – translate into an economical method to measure and predict these changes on site during normal production processes. Goals and Objectives – Dynamic

2. Desired die caster criteria for test High volume runner Multiple cavities (4ea preferred) Flat surface prone to h/c History of rapid h/c Flexible production scheduling Smaller size inserts for handling Reasonable time frame for results Approval of end user Recapping the December 1, 1999 Meeting Notes

3. Bob Ehrman AST Technologies Jerry Skoff Badger Metal Tech Dr. David Schwam Case Western University Nanda Gopal Intermet (was Ganton) Curt Kyonka Pace Industries Vince Adkar Thyssen Steel Yeou-Li Chu Ryobi - via email Committee Members - via email Committee Assistance Members • Arnie Fulton Pace Industries Corp • Jim Berry Pace Industries MO • Roy Cecil Pace Industries MO • Dave Thomason Pace Industries MO • Rex Fish GMPT

4. Current Test Site Pace Industries • 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

5. CASTINGS CAVITY #10 CAVITY #9 Biscuit shot GATE FLOW ON CASTINGS

6. Heat check prone area CAVITY #10

7. Heat check prone area CAVITY #9

8. Shot Biscuit Cavity #9 Approximate area where X-ray and Barkhausen measurements are being taken Directions #1 0 degrees # 2 -45 degrees # 3 -90 degrees Die Sampled 350 SHOTS Photos taken during Pace visit

9. Shot Biscuit Cavity #10 Approximate area where X-ray and Barkhausen measurements are being taken Directions #1 0 degrees # 2 -45 degrees # 3 -90 degrees Die Sampled 350 SHOTS REAR RETAINER Photos taken during Pace visit

10. Die was already sampled (350 shots) (prior to first measurement) Procedure Measurements taken by AST at specified areas determined by past history and Case Western recommendations Die X-ray site plotted for future measurements Barkhausen readings in same locations Inserts returned to Pace for approximately 20-30K shots Repeat measuring cycle for stress and Barkhausen readings until steel upsets & heat checking occurs First Measurement

11. Second Measurement • 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.

13. First & Second Readings No trend established as yet, however, indications of increasing tensile stress developing at measuring point

14. 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

15. Ganton Technologies Rear Seal Cover Side

16. Continue with subsequent X-ray measuring on Pace dies Pursue possibility of working with Ganton (Ford) tooling Next phase - if DOE funding available Begin measuring other tooling that has been surface treated Possible studies Metalife Dyna-blue - Ferritic Nitro-Carburizing Metalife and Dyna-blue in combination Various coatings - i.e.: PVD (Crn, Crc, TiAln) & CVD Future Studies