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Die Materials Development Task Force

Die Materials Development Task Force. NADCA Headquarters November 2, 2005. 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 NADCA Headquarters November 2, 2005

  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 Hub • Four cavity die • One Dievar one Marcast insert • Two Dynablued PG H13 inserts • 332,000 shots • All dies showing heat checks and breakouts. • Dievar had least repairs during run. • Taken out of service. Goal was to hit 250,000-300,000 shots.

  6. The Cast Part

  7. Trials at St. Clair Die Casting Tank Tread Heat Sink • Four Cavity Die • Initial: One Dievar & One QRO-90 Insert • 181,000 Shots, Removed in May ’04 (AM703) • Dievar looks best, slight heat checks (5x life of H13) • 41HRC lowest • QRO-90 welded 5 times, break-out, but better than H13 • 37 HRC lowest • 220,000 Shots, Put Back in Service Jan-Mar ’05 • Removed due to some break-out • New Dievar Die In Operation (AM596) – 173,500 Shots Minimal heat checks at ejectors

  8. Trials at St. Clair Die Casting Tank Tread Heat Sink • 66,200 (AM080) Oct ‘05 • In service Jan ‘05 • High speed machined as opposed to EDM • Showing slight cacking at ejector pins

  9. Trials at St. Clair Die Casting Tank Tread Heat Sink • Pre-hardened Dievar (42-43 HRC) • Placed in service (AM 703) –two cavities. • Couple breakouts/sanding required at 19K for one cavity. • Other cavity breakouts/sanding at 27K • Pulled at 47K. Breakouts and sharp edges increasing.

  10. Tank Tread Heat Sink

  11. Future • Looking at additional materials to test • W403? , Anviloy?, TZM? Others? • Would like at least one more die caster for field testing. • Prefer die with a shorter life. • If St Clair hub: 10” round x 5” • If St Clair heat sink: 8.5” x 10.5” x 2.5” and 8.5” x 10.5” x 2.9” • Any ideas can be forwarded to: jmuha@crucibleresearch.com or udvardy@diecasting.org

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