1. Die Materials Development Task Force NADCA Headquarters November 2, 2005

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 Hub Four cavity die Four cavity die One Dievar one Marcast insert One Dievar one Marcast insert Two Dynablued PG H13 inserts Two Dynablued PG H13 inserts 332,000 shots 332,000 shots –All dies showing heat checks and breakouts. –Dievar had least repairs during run. Taken out of service. Goal was to hit 250,000-300,000 shots. Taken out of service. Goal was to hit 250,000-300,000 shots.

6. The Cast Part

7. Trials at St. Clair Die Casting Tank Tread Heat Sink Four Cavity Die Four Cavity Die Initial: One Dievar & One QRO-90 Insert Initial: One Dievar & One QRO-90 Insert 181,000 Shots, Removed in May ’04 (AM703) 181,000 Shots, Removed in May ’04 (AM703) –Dievar looks best, slight heat checks (5x life of H13)  41HRC lowest –QRO-90 welded 5 times, break-out, but better than H13  37 HRC lowest 220,000 Shots, Put Back in Service Jan-Mar ’05 220,000 Shots, Put Back in Service Jan-Mar ’05 –Removed due to some break-out New Dievar Die In Operation (AM596) – 173,500 Shots Minimal heat checks at ejectors New Dievar Die In Operation (AM596) – 173,500 Shots Minimal heat checks at ejectors

8. Trials at St. Clair Die Casting Tank Tread Heat Sink 66,200 (AM080) Oct ‘05 66,200 (AM080) Oct ‘05 –In service Jan ‘05 –High speed machined as opposed to EDM –Showing slight cacking at ejector pins

9. Trials at St. Clair Die Casting Tank Tread Heat Sink Pre-hardened Dievar (42-43 HRC) Pre-hardened Dievar (42-43 HRC) –Placed in service (AM 703) –two cavities. –Couple breakouts/sanding required at 19K for one cavity. –Other cavity breakouts/sanding at 27K –Pulled at 47K. Breakouts and sharp edges increasing.

10. Tank Tread Heat Sink

11. Future Looking at additional materials to test Looking at additional materials to test –W403?, Anviloy?, TZM? Others? Would like at least one more die caster for field testing. Would like at least one more die caster for field testing. Prefer die with a shorter life. Prefer die with a shorter life. –If St Clair hub: 10” round x 5” –If St Clair heat sink: 8.5” x 10.5” x 2.5” and 8.5” x 10.5” x 2.9” Any ideas can be forwarded to: jmuha@crucibleresearch.com or udvardy@diecasting.org Any ideas can be forwarded to: jmuha@crucibleresearch.com or udvardy@diecasting.org