Presentation is loading. Please wait.

Presentation is loading. Please wait.

NADCA - Die Materials Committee Meeting DIE MATERIALS FOR CRITICAL APPLICATIONS AND INCREASED PRODUCTION RATES Cleveland, OH - November 14, 2001 John F.

Similar presentations


Presentation on theme: "NADCA - Die Materials Committee Meeting DIE MATERIALS FOR CRITICAL APPLICATIONS AND INCREASED PRODUCTION RATES Cleveland, OH - November 14, 2001 John F."— Presentation transcript:

1 NADCA - Die Materials Committee Meeting DIE MATERIALS FOR CRITICAL APPLICATIONS AND INCREASED PRODUCTION RATES Cleveland, OH - November 14, 2001 John F. Wallace David Schwam Quanyou Zhou Case Western Reserve University

2 OUTLINE 1. Shorter cycles - cooling curves in the biscuit. 2. Evaluation of non-ferrous alloys. 3. Results of recently tested die steels.

3 INCREASING PRODUCTIVITY WITH SHORTER CYCLES METHOD: Utilize high thermal conductivity materials to extract heat faster from the large cross sections. EXPERIMENTAL Shot blocks made of H13, Brush Alloy 3 (CuBe-based), Brush MoldMax (CuBe-base), Brush MoldMax XL (copper-base) CMW Anviloy (W), ALLVAC 718 (Ni-base), Nibryl (NiBe). Record cooling curve of the biscuit. Determine “Die Open” time for different shot block materials.

4

5

6

7

8

9 Cooling Curve in the Biscuit with Anvilloy 1150 Shot Block

10 Cooling Curve in the Biscuit with CuBe-C3 Shot Block

11 T H13-Open =28.6(s) T Mold XL-Open =20.0(s) T Anvilloy 1150-Open =23.5(s) T Mold Ma-Open =18.0(s) T CuBe-3C-Open =18.2(s)

12 H13 Anvilloy 3C CuBe

13 Effect of Shot Block Material on Cooling Time of Biscuit Die Open” time (@950 o F)for Brush Alloy 3C is 18.2 sec. vs. 28.6 sec. for H13. This is a 36% reduction in cycle time.

14 LIST OF NON-FERROUS CANDIDATE MATERIALS MaterialCWMoFeNiTiZrCuBeCrNbSn CMW- Anviloy1150 90.004.002.004.00 Kulite-Kuldie90.004.002.004.00 Allvac 718L0.013.1018.2053.800.9317.905.06 CSM-PM Mo100 Brush-QMAX Copper Beryllium 0.20Bal.2.00 Brush-Nybril 360 Nickel Beryllium Bal.0.502.00 Brush-Nybril-FX1 Nickel Beryllium Bal.0.5012.501.00 Brush NBCX Bal.0.512.51.2 Brush M220C 0.4Bal.2.00 Brush ToughMet29.00Bal.6.00 Brush ToughMet315.00Bal.8.00 Nickel Beryllium

15 TOTAL CRACK AREA AFTER 15,000 THERMAL FATIGUE CYCLES (1"x1"x7") 0 100 200 300 400 500 600 Test Materials Total Crack Area (x 10 6 m 2 ) 1"X1"X7", WC7 P.G. H13/Oil/49Rc Bohler W303/Oi/45Rc Brush Wrought Nybril FX/44Rc Brush Cast Nybril FX/49Rc Brush Wrought Nybril 360/35Rc Brush Cast Nybril 360-1/34Rc Brush Cast Nybril 360-2/ 35Rc Bohler W100/44Rc Kind RPU1/48Rc Kind TQ1/48Rc Brush QMAX/24Rc CSM PM Mo/20Rc CMW Anviloy 1150/37Rc Kulite Kuldie/33Rc

16 AVERAGE MAXIMUM CRACK LENGTH AFTER 15,000 THERMAL FATIGUE CYCLES (1"x1"x7") 0 5 10 15 20 25 30 35 40 45 50 Test Materials Average Max Crack Length (x100  m) 1"X1"X7", WC7 Allvac IN718/46Rc (Pitting Depth) P.G. H13/Oil/49Rc Bohler W303/Oi/45Rc Brush Wrought Nybril FX/44Rc Brush Cast Nybril FX/49Rc Brush Wrought Nybril 360/35Rc Brush Cast Nybril 360-1/34Rc Brush Cast Nybril 360-2/ 35Rc Bohler W100/44Rc Kind RPU1/48Rc Kind TQ1/48Rc Brush QMAX/24Rc CSM PM Mo/20Rc CMW Anviloy 1150/37Rc Kulite Kuldie/33Rc

17 Total Crack Area

18 Average Maximum Crack Length

19 Soldering Damage at the Corners of Cu-Ni-Sn Thermal Fatigue Specimens ToughMet 3 ToughMet 2 0.5”

20 Thermal Fatigue Damage in NBCX-1 and M220C-1 NBCX-1 M220C-1 Soldering Thermal Fatigue Cracks Corner 0.5”

21 CORNER DAMAGE IN ALLVAC A-286 (Iron-based w/ca.25% Ni)

22 CermeTi - Titanium Metal Matrix Composite Composition: matrix Ti-6Al-4V + 10wt% TiC particles. Manufacturing: by PM at Dynamet, Burlington MA. Main application: Liner for shot sleeves. Advantages: Low thermal conductivity (5.9 W/mK that is ca. 25% of H13) Good resistance to soldering and dissolving in molten Al Good wear resistance (@40HRC)

23 AVERAGE MAXIMUM CRACK LENGTH OF CermeTi-C-10 vs. H13 0 10 20 30 40 50 60 70 80 0250050007500100001250015000 Thermal Cycles Average Max Crack Length (x100  m) 1"x1"x7", wC7 CermeTi-C-10 H13/oil quench/50HRC

24

25 TOTAL CRACK AREA OF ALLVAC WH38 AND H13 0 50 100 150 200 250 300 350 400 450 500 550 600 650 50007500100001250015000 Thermal Cycles Total Crack Area (x10 6  m 2 ) WH38H13 2"X2"X7", WC7 H13 / OIL / 51HRC WH38 / 50HRC

26 AVERAGE MAXIMUM CRACK LENGTH OF ALLVAC WH38 AND H13 0 5 10 15 20 25 30 35 40 45 50 55 60 50007500100001250015000 Thermal Cycles Average Max Crack Length (x100  m) HW38 H13 2"X2"X7", WC7 H13/ OIL/ 51HRC WH38 / 50HRC

27

28

29

30 TOTAL CRACK AREA OF SCHMIDT H11 AND H13 0 50 100 150 200 50007500100001250015000 Thermal Cycles Total Crack Area (x 10 6  m 2 ) H13SCHMIDT/H11-ESR 2"X2"X7", WC7 H13 / OIL / 51HRC SCHMIDT/H11-ESR/45HRC

31 AVERAGE MAXIMUM CRACK LENGTH OF SCHMIDT H11 AND P.G. H13 0 5 10 15 20 500075001000012500 15000 Thermal Cycles Average Max Crack Length (x100  m) H13SCHMIDT/H11-ESR 2"X2"X7",WC7 H13 / OIL/ 51HRC SCHMIDT/H11-ESR/45HRC

32 TOTAL CRACK AREA OF BOHLER 302 AND P.G. H13 0 50 100 150 200 50007500100001250015000 Thermal Cycles Total Crack Area (x10 6  m 2 ) H13BOHLER W302 2"X2"X7", WC7 H13 / OIL / 51HRC W302/47HRC

33 AVERAGE MAXIMUM CRACK LENGTH OF BOHLER W302 AND P.G. H13 0 5 10 15 20 50007500100001250015000 Thermal Cycles Average Max Crack Length (x100  m) 2"X2"X7", WC7 H13 / OIL/ 51HRC W302/47HRC

34 TOTAL CRACK AREA OF THYSSEN 2344 AND P.G. H13 0 50 100 150 200 50007500100001250015000 Thermal Cycles Total Crack Area (x10 6  m 2 ) 2"X2"X7", WC7 H13 / OIL / 51HRC THYSSEN 2344/45HRC

35 AVERAGE MAXIMUM CRACK LENGTH OF THYSSEN 2344(H13) AND P.G. H13 0 5 10 15 20 50007500100001250015000 Thermal Cycles Average Max Crack Length (x100  m) H132344 2"X2"X7", WC7 H13 / OIL/ 51HRC Thyssen 2344/47HRC

36 TOTAL CRACK AREA OF KIND H11 AND P.G. H13 0 50 100 150 200 250 300 50007500100001250015000 Thermal Cycles Total Crack Area (x10 6  m 2 ) 2"X2"X7", WC7 H13 / OIL / 51HRC KIND H11/47HRC

37 AVERAGE MAXIMUM CRACK LENGTH OF KIND H11 AND P.G. H13 0 5 10 15 20 25 50007500100001250015000 Thermal Cycles Average Max Crack Length (x100  m) 2"X2"X7", WC7 H13 / OIL/ 51HRC KIND H11/47HRC

38

39 AVERAGE MAXIMUM CRACK LENGTH OF KDA1 AND H13 0 2 4 6 8 10 12 14 16 18 50007500100001250015000 Thermal Cycles Average Max Crack Length (x100  m) KDA1H13 2"X2"X7", WC7 H13 KDA1

40

41


Download ppt "NADCA - Die Materials Committee Meeting DIE MATERIALS FOR CRITICAL APPLICATIONS AND INCREASED PRODUCTION RATES Cleveland, OH - November 14, 2001 John F."

Similar presentations


Ads by Google