1. Die Materials Development Task Force
NADCA Headquarters
February 11, 2009

2. Areas of Interest New die materials to increase die life
Ferrous materials
Non-ferrous materials
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 assist in providing information for the Specification Task Force

4. Tank Tread Heat Sink

5. Trials at St. Clair Die Casting
AM703
HRC DieVar High Speed Machined
Anvilloy Cores with reduce length to facilitate heat transfer.
Tool has additional cooling line in each of ejector half inserts between cavities.
0.25” NPT to improve heat removal.
Front and ejector half of die moved 0.375” NPT line from 7/8” to 0.625” below cavity.

6. Trials at St. Clair Die Casting
Currently has 66,507 shots.
Cycle time reduce from 55 sec. to 50 sec.
Can we further reduce with lower oil temp?
Reducing to °F resulted in poor fill.
Best temperature is about 250°F
Inserts
Slight heat checking in all.
Localized breakout in one insert

7. Premier Tool & Die Cast Co
VacDie 34 (Allvac Ni Base Alloy)
Tilt Steering Column 2 Cavity Die
Cooling Passage 0.120”
Initial Machining Difficulties Settled
VacDie 34 used for slide tips.
PG H13
25 K Shots to Crack Initiation
100 K Shots to Die Retirement
Alloy HT in High Strength Condition

8. Premier Tool & Die Cast Co
Cooling lines at 0.5” instead of 0.75” depth
Cracking Noted at 6K Shots
Allvac evaluation
Material failed due to high temperatures which caused surface reactions with molten Al
Water should be used as coolant instead of hot oil
Allvac believes would not fail if kept cool.