1. Die Materials Development Task Force Oak Ridge National Laboratory June 13, 2007

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 Tank Tread Heat Sink Four Cavity Die Four Cavity Die 181,000 Shots, Removed in 5/20/04 181,000 Shots, Removed in 5/20/04 –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 (AM596) – 173,510 Shots Removed 12/12/04 Minimal heat checks at ejectors New Dievar Die (AM596) – 173,510 Shots Removed 12/12/04 Minimal heat checks at ejectors Pre-Hardened Dievar Die (AM703) – 47,000 shots Pre-Hardened Dievar Die (AM703) – 47,000 shots –42-43 HRC –Break-outs and sharp edges –Pulled when AM080 was placed in service

6. Trials at St. Clair Die Casting High Speed Machined Dievar (AM080) High Speed Machined Dievar (AM080) –48- 49 HRC –66,000 shots before breakout –95,000 shots, breakout no worse –122,000 shots, some breakout, some light heat checking. –161,000 shots, some breakout, soon will violate flatness callout. –168,000 shots, no changes. –174,872 shots, no appreciable change.

7. Tank Tread Heat Sink

8. Allvac Nickel Alloys

9. 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 –Ready for in-plant trials

10. VacDie 34 Trial at Premier Tool & Die Cast Corp. Trial at Premier Tool & Die Cast Corp. –Two cavity die – steering column tilt housing –25,000 crack initiation –100,000 shots for replacement Premier has material Premier has material –Got past machining problems –Allvac provided parameters –Die rough machined and heat treated –In final machining