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

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.

9. Cooling Curve in the Biscuit with Anvilloy 1150 Shot Block

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

11. TH13-Open=28.6(s)
TAnvilloy 1150-Open=23.5(s)
TMold XL-Open=20.0(s)
TCuBe-3C-Open=18.2(s)
TMold Ma-Open=18.0(s)

12. H13
Anvilloy
3C CuBe

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

14. LIST OF NON-FERROUS CANDIDATE MATERIALSW Mo Fe Ni Ti Zr Cu Be Cr Nb Sn
CMW-
90.00
4.00
2.00
4.00
Anviloy1150
Kulite-Kuldie
90.00
4.00
2.00
4.00
Allvac 718L
0.01
3.10
18.20
53.80
0.93
17.90
5.06
CSM-PM Mo
100
Brush-QMAX
0.20
Bal.
2.00
Copper Beryllium
Brush-Nybril 360
Bal.
0.50
2.00
Nickel Beryllium
Brush-Nybril-FX1
Bal.
0.50
12.50
1.00
Nickel Beryllium
Brush NBCX
Nickel Beryllium
Bal.
0.5
12.5
1.2
Brush M220C
Nickel Beryllium
0.4
Bal.
2.00
Brush ToughMet2
9.00
Bal.
6.00
Brush ToughMet3
15.00
Bal.
8.00

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

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

17. Total Crack Area

18. Average Maximum Crack Length

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

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

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

23. AVERAGE MAXIMUM CRACK LENGTH OF CermeTi-C-10 vs. H1380 70 60 50
Average Max Crack Length (x100mm) 40
CermeTi-C-10
H13/oil quench/50HRC 30 20 10
1"x1"x7", wC7
2500
5000
7500
10000
12500
15000
Thermal Cycles

25. TOTAL CRACK AREA OF ALLVAC WH38 AND H13
650
2"X2"X7", WC7
600
550
WH38
H13
500
450
400
WH38 / 50HRC
350
Total Crack Area (x106mm2)
300
250
200
H13 / OIL / 51HRC
150
100 50
5000
7500
10000
12500
15000
Thermal Cycles

26. AVERAGE MAXIMUM CRACK LENGTH OF ALLVAC WH38 AND H1360
2"X2"X7", WC7 55
HW38 50
H13 45 40
WH38 / 50HRC
Average Max Crack Length (x100mm) 35 30 25 20
H13/ OIL/ 51HRC 15 10 5
5000
7500
10000
12500
15000
Thermal Cycles

30. TOTAL CRACK AREA OF SCHMIDT H11 AND H13
200
2"X2"X7", WC7
H13
SCHMIDT/H11-ESR
150
SCHMIDT/H11-ESR/45HRC
Total Crack Area (x 106mm2)
100 50
H13 / OIL / 51HRC
5000
7500
10000
12500
15000
Thermal Cycles

31. AVERAGE MAXIMUM CRACK LENGTH OF SCHMIDT H11 AND P.G. H1320
H13
SCHMIDT/H11-ESR 15
SCHMIDT/H11-ESR/45HRC
Average Max Crack Length (x100mm) 10
H13 / OIL/ 51HRC 5
2"X2"X7",WC7
5000
7500
10000
12500
15000
Thermal Cycles

32. TOTAL CRACK AREA OF BOHLER 302 AND P.G. H13
200
2"X2"X7", WC7
H13
BOHLER W302
150
Total Crack Area (x106mm2)
W302/47HRC
100 50
H13 / OIL / 51HRC
5000
7500
10000
12500
15000
Thermal Cycles

33. AVERAGE MAXIMUM CRACK LENGTH OF BOHLER W302 AND P.G. H1320
2"X2"X7", WC7 15
Average Max Crack Length (x100mm) 10
W302/47HRC 5
H13 / OIL/ 51HRC
5000
7500
10000
12500
15000
Thermal Cycles

34. TOTAL CRACK AREA OF THYSSEN 2344 AND P.G. H13
200
2"X2"X7", WC7
150
Total Crack Area (x106mm2)
H13 / OIL / 51HRC
100 50
THYSSEN 2344/45HRC
5000
7500
10000
12500
15000
Thermal Cycles

35. AVERAGE MAXIMUM CRACK LENGTH OF THYSSEN 2344(H13) AND P.G. H1320
2"X2"X7", WC7
H13
2344 15
H13 / OIL/ 51HRC
Average Max Crack Length (x100mm) 10 5
Thyssen 2344/47HRC
5000
7500
10000
12500
15000
Thermal Cycles

36. TOTAL CRACK AREA OF KIND H11 AND P.G. H13
300
2"X2"X7", WC7
250
200
KIND H11/47HRC
Total Crack Area (x106mm2)
150
100 50
H13 / OIL / 51HRC
5000
7500
10000
12500
15000
Thermal Cycles

37. AVERAGE MAXIMUM CRACK LENGTH OF KIND H11 AND P.G. H1325
2"X2"X7", WC7 20
KIND H11/47HRC 15
Average Max Crack Length (x100mm) 10 5
H13 / OIL/ 51HRC
5000
7500
10000
12500
15000
Thermal Cycles

39. AVERAGE MAXIMUM CRACK LENGTH OF KDA1 AND H1318 16 m) m
KDA1
H13 14
H13 12 10
Average Max Crack Length (x100 8 6
KDA1 4 2
2"X2"X7", WC7
5000
7500
10000
12500
15000
Thermal Cycles