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Aluminum has 5 times better heat transfer than P20 steel Aluminum has almost 6 times better heat transfer compared to H-13 Steel. Molders have experienced a 20% to 40% faster cycle time. Toll Free #

Aluminum Mold can be machined up to 30% faster overall with appropriate high speed CNC machines and cutting tools specifically designed for aluminum Polishing time is reduced. Aluminum is 1/3 the weight of steel. Service Centers can ship aluminum within 1-3 days, versus steel. Toll Free #

Aluminum alloys offer higher thermal conductivity, so the parts are removed at a lower temperature. This leads to better dimensional stability of parts providing higher yields on the molding process. Toll Free #

Cast product with three North American Producers Available in North American up to 30" thick and 74" wide (only 20 thick at this width) This alloy is for low volume or prototype molds. No abrasive plastics Drawbacks Heat transfer is slower due to the low copper content / Cycle times are going to be slightly lower than other aluminums Hardness is low 70 HB yield and tensile strengths are lower than other aluminums available Because of the hardness a high polish is hard to achieve Benefits Cost - Weight.96 dense because its a cast plate cost is much less than rolled or forged block Machinability is very good due to the lack of copper content stability is the best of any aluminum Has great weldability because copper content is low the corrosion resistance is very high sizes available through hardness Toll Free # Trade Names: Alpase – K100S & M 5 Vista – ATP-5 & Duramold 5

Cast product with two North American Producers This alloy has higher yield and tensile strengths than 6061 with hardness very close to 6061 can be used for low volume production and prototype tools sizes available 38 thick 94 wide Drawbacks Machinability (This is within the aluminums available / Still would machine much better than steel) Chips might stick to cutters gummy. hardness is low (again within the aluminums available) 82 to 90HB Polishability Benefits Cost compared to 6061/ 7000 weldability heat transfer very high yield and tensile strength are high compared to 6061 sizes available through hardness Toll Free # Trade Names: Alpase – M1 Vista – Duramold 2

rolled plate 16 thick 84 wide 192 long Drawbacks Machinability is poor hardness HB Polishability Benefits thermal transfer rate is high cost compared to 7000 series weldability Toll Free # Trade Names: Kaiser select

Three available alloys besides 7075 available 28 thick in forged block Drawbacks Weldability / Can be welded but you have to follow the welding instructions very carefully Stability - All 7000 series can move during machining if not stress relieved Benefits BTu's are very high Machinability Yield and Tensile strengths are very high sizes available Hardness HB Polishability A mirror finish is achievable Toll Free # Trade Names: Aleris – Hokotol Alcan – Alumold 7075 – General product

Their approach for reviewing Aluminum Alloy 1. Met with key Aluminum Alloy Material Suppliers 2. Honda paid for 3rd Party Testing to validate Material composition, mechanical properties, abrasion resistance and compression strength. 3. Concluded that Honda should begin working with its suppliers to build Aluminum Alloy Tools. (ZQ/WQ) 4. Honda decided to build aluminum tools and pay for the backup Steel Tool Purpose: a. Review Clamping pressure b. Review injection pressure c. Evaluate Tool build efficiencies d. Evaluate Process Cycle time 5. Honda paid for Texture plaque development to further understand Aluminum Alloy texture capabilities as well as repair methods. 6. Monitor Tool Maintenance and durability concerns 7. Based on Low Volume Results, began focusing on High Volume applications to validate AL Alloy durability.

Can the mold be crushed by too much pressure? Unit stress = load/area Projection area of mold = 46 x74 = 3404 in2 Projection area of part = 955 in2 Contact area = = 2449 in2 Stress (2500 ton press) =5,000,000 / 2449 = 2, psi 7050 tensile strength 77,600 psi In this example, the clamping stress is only 2.6 % of the AL Alloy Tensile Strength

Will Aluminum Alloy handle high Injection pressure without failure? Compressive strength of alloy – 77,600 psi Maximum injection pressure at the front of the screw (regardless of machine size) – 33,000 psi Percentage –33,000 / 77,600 = 42.5% of maximum at highest possible pressure

Tool Lead Time Comparison of Mold Builds P20 Steel vs. Aluminum Alloy

Review – Investment Cost

The parts are removed at a lower temperature, resulting in less distortion and higher quality.

Review - Welding 7000 series welding improvements are being investigated.

Recommendations P20 / S55C Steel 4130 / sd18 Soft Steel 7000 Series Aluminum Alloy M1 & & 7000 Hybrid M1 Cast 100,000500,0001,000,0001,500,0002,000,0002,500,0003,000,000 Approximate Number of shots

1. Investment savings through machining efficiencies. 2. Process savings through improved thermal conductivity. (cycle time) 3. Reduce number of molds and injection machines required to mold the parts. 4. Different grades of aluminum can be applied based on Program volume. 5. Lower injection and clamp pressure required as compared to tool steel. 6. Plastic parts released from the molds at lower temperatures, resulting in less product distortion. Toll Free #

Thank You! Toll Free # We would like to Thank Honda of America Mfg., Inc. for allowing us to utilize their data to continue to educate the Aluminum Injection Mold Industry.