1. Die Materials Development Task Force Update
NADCA
February 21, 2007

2. Areas of Interest New die materials to increase die life
Ferrous materials
Non-ferrous materials

3. Goal
To obtain field information to validate laboratory testing information
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 to log information for appropriate record keeping on form that was developed

5. Trials at ????? Die Casting Hub Four cavity die
One Dievar one Marcast insert
332,000 shots, Out of Service 7/1/05
Dievar looks best – slight washout, minimal heat check at ejector pins
Marcast more checking than H13
Goal 250, ,000 shots

6. The Hub Cast Part

7. Trials at ???? (protected) Tank Tread Heat Sink Four Cavity Die
One Dievar & One QRO-90 Insert, AM703
181,000 Shots, Removed from service May, 2004
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
Dievar Die (AM596) – 174,000 Shots Heat checks at ejectors and front half required regular repair. Taken out of service 12/13/04

8. Tank Tread Heat Sink

9. Tank Tread Heat Sink
Heat checked and breakout area

10. Trials at ???? (protected)
Pre-hardened Dievar insert w/ 181K shot Dievar insert, AM703
HRC, pre-hardened Dievar
Sanding of breakouts required after 19K shots.
Pulled after 47,000 shots on pre-hardened Dievar, 220K shots on conventional Dievar
High speed machined Dievar, AM080
HRC
66,000 shots before breakout
95,000 shots, breakout no worse
122,000 shots, same breakout, some light heat checking (June ’06)
Now 161,00 shots, (Feb. 07) breakout slightly increasing, still acceptable.

11. Other Future Bohler W360 ISO Bloc Bohler W400 VMR Lower Si, Higher Mo
Capable of 58 HRC
Good toughness for hardness level
Commercially available
Bohler W400 VMR
When cracking is a major issue
50-52 HRC