1. March 30, 2000 Residual Stress Report Die Materials Committee Meeting March 30, 2000 Page 1 of 15 è Determine through baseline test measurements the stress changes that occur during production cycles. è Monitor these changes at specific historic area/areas where upset heat checking first occurs. è Phase II - Using this information see what effect different surface modifications have on this baseline data. è Knowing this – translate into an economical method to measure and predict these changes on site during normal production processes. Goals and Objectives – Dynamic

2. March 30, 2000 Residual Stress Report Die Materials Committee Meeting March 30, 2000 Page 2 of 15 è Desired die caster criteria for test  High volume runner  Multiple cavities (4ea preferred)  Flat surface prone to h/c  History of rapid h/c  Flexible production scheduling  Smaller size inserts for handling  Reasonable time frame for results  Approval of end user Recapping the December 1, 1999 Meeting Notes

3. March 30, 2000 Residual Stress Report Die Materials Committee Meeting March 30, 2000 Page 3 of 15  Bob  Bob Ehrman AST Technologies  Jerry  Jerry SkoffBadger Metal Tech  Dr.  Dr. David SchwamCase Western University  Nanda  Nanda GopalIntermet (was Ganton)  Curt  Curt KyonkaPace Industries  Vince  Vince AdkarThyssen Steel  Yeou-Li  Yeou-Li ChuRyobi Committee Assistance Members  Arnie  Arnie FultonPace Industries Corp  Jim  Jim BerryPace Industries MO  Roy  Roy CecilPace Industries MO  Dave  Dave ThomasonPace Industries MO  Rex  Rex FishGMPT Committee Members - via email

4. March 30, 2000 Residual Stress Report Die Materials Committee Meeting March 30, 2000 Page 4 of 15  high volume runner  multiple cavities  flat surface prone to h/c  history of rapid h/c  flexible production schedule  smaller size inserts for handling  reasonable time frame for results  approval of end user Current Test Site Pace Industries

5. March 30, 2000 Residual Stress Report Die Materials Committee Meeting March 30, 2000 Page 5 of 15 CASTINGS GATE FLOW ON CASTINGS CAVITY #10CAVITY #9 Biscuit shot

6. March 30, 2000 Residual Stress Report Die Materials Committee Meeting March 30, 2000 Page 6 of 15 Heat check prone area CAVITY #10

7. March 30, 2000 Residual Stress Report Die Materials Committee Meeting March 30, 2000 Page 7 of 15 CAVITY #9 Heat check prone area

8. March 30, 2000 Residual Stress Report Die Materials Committee Meeting March 30, 2000 Page 8 of 15 Cavity #9 Photos taken during Pace visit Shot Biscuit Die Sampled 350 SHOTS Approximate area where X-ray and Barkhausen measurements are being taken Directions #1 0 degrees # 2 -45 degrees # 3 -90 degrees

9. March 30, 2000 Residual Stress Report Die Materials Committee Meeting March 30, 2000 Page 9 of 15 Cavity #10 REAR RETAINER Photos taken during Pace visit Shot Biscuit Die Sampled 350 SHOTS Directions #1 0 degrees # 2 -45 degrees # 3 -90 degrees Approximate area where X-ray and Barkhausen measurements are being taken

10. March 30, 2000 Residual Stress Report Die Materials Committee Meeting March 30, 2000 Page 10 of 15  Die was already sampled (350 shots) (prior to first measurement) (prior to first measurement) Procedure Procedure  Measurements taken by AST at specified areas determined by past history and Case Western recommendations  Die X-ray site plotted for future measurements  Barkhausen readings in same locations  Inserts returned to Pace for approximately 20-30K shots  Repeat measuring cycle for stress and Barkhausen readings until steel upsets & heat checking occurs First Measurement

11. March 30, 2000 Residual Stress Report Die Materials Committee Meeting March 30, 2000 Page 11 of 15  Die had 20,523 shots (producing castings (03/29/2000) (Will attempt to pull every 20-30K- takes 2 weeks)  AST commented that, upon receipt, they noted that the calibration area selected on the dies for the 1st measurement appeared to be aggressively ground.  Same reference point used for measurement #1 would make Barkhausen readings (which measures change) not usable.  New calibration piece for reference was made by AST but not from (H-13).  Measurements taken and returned to Pace. Second Measurement

12. March 30, 2000 Residual Stress Report Die Materials Committee Meeting March 30, 2000 Page 12 of 15

13. March 30, 2000 Residual Stress Report Die Materials Committee Meeting March 30, 2000 Page 13 of 15 No trend established as yet, however, indications of increasing tensile stress developing at measuring point

14. March 30, 2000 Residual Stress Report Die Materials Committee Meeting March 30, 2000 Page 14 of 15 Possible Future Testing: Ganton Technologies  high volume runner  multiple cavities  flat surface prone to h/c  history of rapid h/c  flexible production schedule  smaller size inserts for handling  reasonable time frame for results  approval of end user

15. March 30, 2000 Residual Stress Report Die Materials Committee Meeting March 30, 2000 Page 15 of 15 Ganton Technologies Rear Seal Cover Side

16. March 30, 2000 Residual Stress Report Die Materials Committee Meeting March 30, 2000 Page 16 of 15  Continue with subsequent X-ray measuring on Pace dies  Pursue possibility of working with Ganton (Ford) tooling Next phase - if DOE funding available  Begin measuring other tooling that has been surface treated Possible studies Possible studies  Metalife  Dyna-blue - Ferritic Nitro-Carburizing  Metalife and Dyna-blue in combination  Various coatings - i.e.: PVD (Crn, Crc, TiAln) & CVD Future Studies