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

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. Tank Tread Heat Sink

5. Trials at St. Clair Die Casting AM703 AM703 –48- 50 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. Currently has 66,507 shots. Cycle time reduce from 55 sec. to 50 sec. Cycle time reduce from 55 sec. to 50 sec. –Can we further reduce with lower oil temp?  Reducing to 230-240°F resulted in poor fill.  Best temperature is about 250°F Inserts Inserts –Slight heat checking in all. –Localized breakout in one insert

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

8. Premier Tool & Die Cast Co Cooling lines at 0.5” instead of 0.75” depth Cooling lines at 0.5” instead of 0.75” depth Cracking Noted at 6K Shots Cracking Noted at 6K Shots Allvac evaluation 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.