North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA 4 Success Stories T Jerald (Jerry) V. Skoff - Founder Badger Metal Tech, Inc. Benefits of Compressive Stress Surface Engineering

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA Fill Problem - FiveStar Case C0987 MN – 2008 – Bake Pan FiveStar Blistering in cosmetic area of brownie pan Teflon coating adhesion problem 40 parts scrapped in 10 hour shift

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA Solution to Fill - FiveStar FiveStar Compressive Stress processing T41 – 5-6C Almen – 460 media 10A A – GB Cover and Ejector plus Gate

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA FiveStar - Photo

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA Five Star - ROI Benefits FiveStar Laminar fill disappeared Blistering stopped Metal flow improved Scrap dropped from 40 to 2 castings/10 hr shift 95% reduction

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA Heat Checking Problem - Kirby Case C0082 TX – 2008 – Vacuum Cleaner Kirby Non cosmetic & Cosmetic 6-7 components 30-35K Heat check would start on new tooling

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA Solution to Heat Checking - Kirby Kirby Compressive Stress processing T41 – 5-6C Almen – 460 media 10A A – GB Entire cast area of cosmetic side/sides New tooling with polished castings

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA Kirby - Photos

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA ROI Benefits - Kirby Kirby No heat checking until 93K shots 3x 200% increase (30-35K before) Better castings, easier to polish No hidden porosity or inclusions Begin doing on all dies including auto finish high buff castings

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA Shortened tool life problem - Toro Case C0266 – MN – Mower Decks Toro Thick wall castings – 150K life Gate velocity ft/sec Good SPC

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA Toro - Photos

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA Toro Compressive Stress Processing T40H – 8-9C Almen – 460 media 4A – GB Entire cast areas – cosmetic Also some inserts that soldered received PM program every season In place for 18 years Solution to short tool life - Toro

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA ROI Benefits - Toro Toro Reduced casting defects Less die welding Scrap rate reduction Improved flow Paint adhesion Large return on investment from 150K to increase of 370K+ (+146%)

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA Find effective PM program - Lamar Aluminum C0670 – CA Lamar Die Casting Vendo – vending machine parts Before 180K for Vendo Gauge Bar & Gate 380 aluminum Bronwite - Brass Weather-Tec – impact sprinkler heads Before 100,000 parts (8 cav) Weathertec (1550 [1625] degree F Bronwite metal) CC99750 (brass 60% Cu, 20% Mn)

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA Lamar - Photo

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA Solution to PM Search - Lamar Lamar Vendo Gauge Bar & Gate - (75K, every 100K) High Production – 520K/yr 180K to 420K Avg each die (+133%) Weather-Tec Sprinkler Head High production From 100K to 200K+ – Still producing parts

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA More Case Studies Breakout & Pitting from cavitation effect C0027, C0258, C0376, C0834, C0542, etc. Heat Checking – C0001, C0870, C0753, C0321 Soldering – C0704, C0670, C0481 Porosity - C0274, C0693, C0150 Flow Problems – C0031, C0025, C0609 Laminar Fill – C0274, C

North American Die Casting Association – 113 th Metalcasting Congress April 7-10, 2009 Las Vegas, NV USA Case Studies