1. Die Materials Development Task Force Case Western Reserve University June 14, 2006

2. Areas of Interest New die materials to increase die life New die materials to increase die life – Ferrous materials – Non-ferrous materials New die materials to decrease cycle time – (i.e. increase productivity) 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 obtain field information to validate laboratory testing information To assist in providing information for the Specification Task Force 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 multi-cavity die or single die with documented history. Need to log information for appropriate record keeping on form that was developed Need to log information for appropriate record keeping on form that was developed

5. Trials at St. Clair Die Casting Hub Four cavity die Four cavity die One Dievar one Marcast insert One Dievar one Marcast insert Two Dynablued PG H13 inserts Two Dynablued PG H13 inserts 205,000 shots 205,000 shots –Dievar looks best – slight washout, minimal heat check at ejector pins –Marcast more checking than H13 Would like to hit 250,000-300,000 shots Would like 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 Four Cavity Die One Dievar & One QRO-90 Insert One Dievar & One QRO-90 Insert 181,000 Shots, Removed in May 181,000 Shots, Removed in May –Dievar looks best, slight heat checks (5x life of H13)  41HRC lowest  Placed back in AM703, run to 220,000 shots –QRO-90 welded 5 times, break-out, but better than H13  37 HRC lowest New Dievar Die In Operation (AM596) – 171,000 Shots Minimal heat checks at ejectors New Dievar Die In Operation (AM596) – 171,000 Shots Minimal heat checks at ejectors

8. Trials at St. Clair Die Casting Pre-hardened Dievar Pre-hardened Dievar –42- 43 HRC –Pulled after 47,000 shots High speed machined Dievar High speed machined Dievar –48- 49 HRC –66,000 shots before breakout –95,000 shots, breakout no worse –122,000 shots, same breakout, some light heat checking (June ’06) –Now 134,800 shots, no noticeable difference

9. Tank Tread Heat Sink

10. Allvac Nickel Alloys

11. Tested numerous alloys Tested numerous alloys Found that nickel alloys were cracking by corrosion fatigue, not thermal fatigue. Found that nickel alloys were cracking by corrosion fatigue, not thermal fatigue. VacDie 34 VacDie 34 –Heat treatment makes difference –TMP is important

12. Ready for field test

13. VacDie 34 Field Trial Allvac willing to put money in. Allvac willing to put money in. Allvac to be involved in die design. Allvac to be involved in die design. Run die to failure. Run die to failure. Erosion/washout unknown. Erosion/washout unknown.

14. VacDie 34 Trials at St. Clair and Premier Diecasting Trials at St. Clair and Premier Diecasting Need more material Need more material Commercial heat to be made soon Commercial heat to be made soon

15. Other Future Bohler W360 ISO Bloc Bohler W360 ISO Bloc –Lower Si, Higher Mo –Capable of 58 HRC –Good toughness for hardness level –Commercially available