die materials development task force nadca headquarters november 2, 2005
TRANSCRIPT
Die Materials Die Materials DevelopmentDevelopment Task Force Task Force
NADCA HeadquartersNADCA Headquarters
November 2, 2005November 2, 2005
Areas of InterestAreas of Interest
New die materials to increase die life New die materials to increase die life – Ferrous materialsFerrous materials– Non-ferrous materialsNon-ferrous materials
New die materials to decrease cycle New die materials to decrease cycle time – (i.e. increase productivity) time – (i.e. increase productivity) – High thermal conductivity materials High thermal conductivity materials
GoalGoal
To obtain field information to validate To obtain field information to validate laboratory testing informationlaboratory testing information
To assist in providing information for To assist in providing information for the Specification Task Forcethe Specification Task Force
Trials at Die CasterTrials at Die Caster
Need multi-cavity die or single die Need multi-cavity die or single die with documented history. with documented history.
Need to log information for Need to log information for appropriate record keeping on form appropriate record keeping on form that was developedthat was developed
Trials at St. ClairTrials at St. Clair Die Casting Die Casting
HubHub Four cavity dieFour cavity die One Dievar one Marcast insertOne Dievar one Marcast insert Two Dynablued PG H13 insertsTwo Dynablued PG H13 inserts 332,000 shots 332,000 shots
– All dies showing heat checks and All dies showing heat checks and breakouts. breakouts.
– Dievar had least repairs during run. Dievar had least repairs during run. Taken out of service. Goal was to hit Taken out of service. Goal was to hit
250,000-300,000 shots.250,000-300,000 shots.
The Cast PartThe Cast Part
Trials at St. Clair Die Trials at St. Clair Die CastingCasting
Tank Tread Heat SinkTank Tread Heat Sink Four Cavity DieFour Cavity Die Initial: One Dievar & One QRO-90 InsertInitial: One Dievar & One QRO-90 Insert 181,000 Shots, Removed in May ’04 (AM703)181,000 Shots, Removed in May ’04 (AM703)
– Dievar looks best, slight heat checks (5x life of H13)Dievar looks best, slight heat checks (5x life of H13) 41HRC lowest 41HRC lowest
– QRO-90 welded 5 times, break-out, but better than QRO-90 welded 5 times, break-out, but better than H13H13 37 HRC lowest37 HRC lowest
220,000 Shots, Put Back in Service Jan-Mar ’05220,000 Shots, Put Back in Service Jan-Mar ’05– Removed due to some break-outRemoved due to some break-out
New Dievar Die In Operation (AM596) – New Dievar Die In Operation (AM596) – 173,500 Shots Minimal heat checks at ejectors173,500 Shots Minimal heat checks at ejectors
Trials at St. Clair Die Trials at St. Clair Die CastingCasting
Tank Tread Heat SinkTank Tread Heat Sink 66,200 (AM080) Oct ‘0566,200 (AM080) Oct ‘05
– In service Jan ‘05 In service Jan ‘05 – High speed machined as opposed to EDMHigh speed machined as opposed to EDM– Showing slight cacking at ejector pinsShowing slight cacking at ejector pins
Trials at St. Clair Die CastingTrials at St. Clair Die Casting
Tank Tread Heat SinkTank Tread Heat Sink Pre-hardened Dievar (42-43 HRC)Pre-hardened Dievar (42-43 HRC)
– Placed in service (AM 703) –two cavities.Placed in service (AM 703) –two cavities.– Couple breakouts/sanding required at Couple breakouts/sanding required at
19K for one cavity.19K for one cavity.– Other cavity breakouts/sanding at 27KOther cavity breakouts/sanding at 27K– Pulled at 47K. Breakouts and sharp Pulled at 47K. Breakouts and sharp
edges increasing. edges increasing.
Tank Tread Heat SinkTank Tread Heat Sink
FutureFuture Looking at additional materials to testLooking at additional materials to test
– W403? , Anviloy?, TZM? Others?W403? , Anviloy?, TZM? Others? Would like at least one more die caster Would like at least one more die caster
for field testing.for field testing. Prefer die with a shorter life.Prefer die with a shorter life.
– If St Clair hub: 10” round x 5”If St Clair hub: 10” round x 5”– If St Clair heat sink: 8.5” x 10.5” x 2.5” and If St Clair heat sink: 8.5” x 10.5” x 2.5” and
8.5” x 10.5” x 2.9” 8.5” x 10.5” x 2.9” Any ideas can be forwarded to: Any ideas can be forwarded to:
[email protected] or [email protected] or [email protected]@diecasting.org