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DIE MATERIALS & TECHNOLOGIES

2009

NORTH AMERICAN DIE CASTING ASSOCIATION

HIGH PRODUCTION RATE TOOLING

D. Schwam, Case Western Reserve University

Project Objectives: High productivity is the ultimate driver for most process improvements. In die casting, increasing productivity is to a large extent determined by the cycle time. In turn, the cycle time depends on the ability of the cooling system to extract the heat from the dies. Ideally, this function is performed by optimized design of the internal cooling lines and use of high thermal conductivity die materials for rapid heat extraction from the casting. This project was designed as an in-plant experimental program to determine the potential for cycle time reduction by aggressive placement of cooling lines and use of high thermal conductivity cores. Approach: Traditional design of the cooling lines is an iterative process that targets a balance between the heat input from the molten metal and the heat extracted by the coolant. At the end of this process, the designer will have a schematic of the die with the required water or oil line sizes and routing. The heat input is determined mainly by the weight and the total surface of the casting, the cycle time, and the alloy cast. This heat must be extracted by locating appropriate cooling lines in proximity to the cavity. It is common practice to divide the casting into segments, and calculate the heat balance individually for each segment. The length of the cooling line is determined based on heat transfer calculations. In general, cooling lines located closer to the surface of the cavity are more effective in removing heat. However, the industry has adopted thumb rules relative to the depth of the cooling lines that provide a safeguard from catastrophic cracking of the die. These thumb rules suggest a minimum distance of 0.75 between the water cooling lines and the surface of the cavity. This distance can be reduced to 0.5 in the case of oil lines. According to these thumb rules, drilling cooling lines closer to the surface increases the risk of gross cracking, i.e., catastrophic cracking due to excessive thermal stresses. The nancial liability associated with cracking a die is signicant. Consequently, designers have been taking a conservative approach by following these guidelines. However, anecdotal evidence suggests that cooling lines can be placed closer to the surface. Considering modern advances in steel quality and heat treat specications, this option should be explored, especially when the die develops hot spots that result in soldering and downtime. The main reason to experiment with more efcient internal cooling is the potential for shorter cycle time. The end result of shorter cycle time is a more productive die casting operation. Results: The project was conducted in collaboration with St. Clair Die Casting, St. Claire, MO. A four cavity die making aluminum heat sinks, about 4.5x2.5x1.15 weighing 1.1 pounds each, was built for this study. A superior tool

steel with higher toughness of over 20 ft-lbs, compared to 10-12 ft-lbs typical in Premium Grade H13 was used. The higher toughness minimizes the risk of gross cracking due to increased thermal gradients when cooling lines are closer to the surface. The cast parts are chunky and have a larger weight to volume ratio than typical die castings. This means a relatively large amount of heat needs to be extracted after each shot in order to bring the die back to the required temperature before the next shot can be made. The potential for faster extraction of the heat by improved cooling line design is high. Another advantage of this die set is the existing base-line of operating conditions and performance from a previous study. An identical die has been in use for the last four years. The die was re-designed by bringing the cooling lines closer to the surface. The H13 core pins were substituted with Anviloy to further enhance heat extraction during solidication. Subsequently it was operated with progressively shorter cycle times while monitoring the die temperature. A long term goal is to determine potential changes in die life. The rst step in the project was to re-design the size and location of the cooling lines. The distance of the cooling lines from the surface of the die has been reduced from 0.87 to 0.5. A detailed ow and solidication computer simulation was conducted to determine the effect of the changes in the cooling line conguration. The simulation is used to verify the design of the gating and cooling system in regard to the cooling line size and location; it will indicate any hot spots in the die or areas where the molten metal becomes too cold to ll the mold. In such cases, the cooling line design is modied and the simulation is repeated until a satisfactory temperature distribution is obtained. This procedure is also effective in preventing shrinkage porosity associated with undesirable hot spots in the casting. The simulation predicted a cycle time shorter by 20% relative to the original cooling line design. To conrm the results of the simulation, the cycle time feasible with the re-designed cooling system was measured in production runs. Embedding thermocouples in the inserts and attaching them to a data acquisition system was used to monitor the temperature. A high temperature ow meter was installed to measure the ow of the cooling medium in the inserts. The cycle for die casting the tank thread heat sinks could be shortened by 13% by improved heat extraction into water cooling lines drilled closer to the surface. A set of inserts was fabricated out of a tool steel with superior toughness of over 20 ft-lbs, compared to 10-12 ftlbs typical in Premium Grade H13. The higher toughness minimizes the risk of gross cracking due to increased

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Figure 1. Oil (V04) vs. Water (V05) comparison when moving lines closer to the cavity surface. Computer simulation predicted a 20-40% cycle time reduction. Measured reduction was 13% when oil was used in the lines.

thermal gradients when cooling lines are closer to the surface. Production runs with the improved dies have demonstrated a reduction of 13% in cycle time. Further reductions in cycle time are anticipated by replacing the oil with water-cooling. Implementation Strategy: Die steels with superior toughness as compared to Premium Grade H13 are now available. These die materials offer the die caster with an opportunity to move cooling lines closer to the cavity surface for faster heat removal and lower cycle times. The die caster should consider using new materials and placing cooling lines closer to the cavity surface. Consult with the researcher and die material suppliers to obtain guidance for placing cooling lines at a safe distance from the cavity surface.
Monitoring Task Force: Die Materials Committee Sponsored by: DoD-ARDEC, Picatinny, NJ and Benet Laboratories, Watervliet, NY and NADCA

For further information, contact: North American Die Casting Association 847.279.0001 phone 847.279.0002 fax www.diecasting.org/research research@diecasting.org

NORTH AMERICAN DIE CASTING ASSOCIATION

241 Holbrook Dr. Wheeling, IL 60090 Email: research@diecasting.org www.diecasting.org/research

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INTEGRATION OF RSP TOOLING WITH RP FOR DIE CASTING APPLICATIONS

J. Folkestad, Colorado State University; J. Knirsch, RSP Tooling, LLC; K. McHugh, Idaho National Engineering and Environmental Laboratory

Project Objectives: The objective of this project is to develop and utilize RSP Tooling within the die casting industry by introducing a new tooling technology that will reduce lead times, extend die life, and reduce energy consumption. Approach: The Rapid Solidication Process (RSP) was developed at INEEL under grants from the DOE. The initial patent for the process was written in 1990 and had as its basis the invention or discovery that a liquid could be broken down into small droplets by use of the shearing effect of a owing gas. There are a large number of possible applications of this invention. An early application of the process was the production of low-carbon steel strip, the industrys highest volume commodity. There are many advantages to producing strip using RSP, but the most signicant to DOE was a signicant reduction in energy use. Work on the process resulted in another patent in 1995 which introduced the use of the pressurized injection of liquid into a Ventura tube, thereby improving the operational exibility of the device while producing a more uniform droplet size distribution. An additional benet was the ability to control and increase the cooling rate of the droplets, which results in microstructure and material property improvements in the deposited metal. Since the grain structure of the spray deposited metal was good, as was the ability of the spray deposited metal to replicate complex surface shapes, the idea of using the process to manufacture tools was developed. This resulted in two things: a new patent in 1997, and the terminology of RSP Tooling. Additional patent applications have been submitted, which rene the actual process to produce tooling. RSP Tooling is a spray forming technology tailored for producing molds and dies. The process allows the die caster to build production tooling in the time it usually takes Figure 1. Process Sketch

to make prototype tooling. This means that the prototypes can be made from the actual production process and the time normally needed to produce the production tooling disappears. Furthermore, very little is sacriced by using the RSP process and there is strong evidence that this rapid tooling approach may increase tool life compared to conventional tooling made from the same alloy. Results: Although the RSP Tooling process can manufacture tooling for any forming process from virtually any tooling material, it is of signicant benet to die casting. This is true because of the added benets that develop when spray forming H-13 and because of the nature and expense of die cast tooling. The speed of the process allows the die caster to compete with standard prototype sources for producing prototypes in the required timing. This benets the customer by receiving a prototype made from the production process instead of an alternative process providing different properties. Another benet is that the time while the prototype is being tested can be used to develop the die cast process. In normal practice, the prototype testing period is idle time to the die caster. With this tooling, the high quality production process can be developed during the prototype period without the pressure of meeting production delivery times. The benets to the die caster dont stop at die build. There is strong evidence developed from actual production testing that the RSP tool is more resistant to wear, heat checking and soldering than the standard heattreated steel insert. This reduces the ongoing high cost of die maintenance and replacement tooling. When the tool does need to be replaced, the amount of time needed to build the replacement component is cut substantially, further reducing the need for large tooling inventories. The benets of the RSP Tooling process can be summarized as: Reduces tooling lead time. Reduces tooling cost, especially for replacement tooling. Can be articially aged and does not need to be heat treated. Increased tool life. The process can use standard H-13 in place of premium grade H-13 and can probably use recycled materials. The process eliminates the need to build prototype tooling. The process can replicate details smaller than what can normally be machined.

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Implementation Strategy: Die casters should evaluate the potential of RSP Tooling to reduce the cost of die cast tooling. Especially die casters who utilize small dies may be able to substantially reduce the cost and lead time for dies. Figure 2. Machine Process

Monitoring Task Force: Die Materials Committee Sponsored by: U.S. Department of Energy and NADCA This research is featured in more detail in the following transactions: T02-051 and T05-053

RSP Tooling, LLC, was formed in January 2002 to design, build, use and sell machines that manufacture tooling using this process. A production machine is in operation which can produce a 50-pound steel insert (6x6x4) every two hours. Die inserts are being produced for various processes, including die casting. The RSP technology has the potential to eliminate a substantial bottleneck for die casters, tooling lead time, while potentially providing longer lasting tooling as well. Figure 3. Rapid Solidication in Action

For further information, contact: North American Die Casting Association 847.279.0001 phone 847.279.0002 fax www.diecasting.org/research research@diecasting.org

NORTH AMERICAN DIE CASTING ASSOCIATION

241 Holbrook Dr. Wheeling, IL 60090 Email: research@diecasting.org www.diecasting.org/research

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RAPID TOOLING FOR LOW VOLUME DIE CASTING

J. Wallace and D. Schwam, Case Western Reserve University

Project Objectives: Rapid prototyping casting methods are often employed when a small number of cast parts are needed. The casting method of choice is dictated by the dimensional accuracy, mechanical properties and surface nish required of the parts. Sometimes the desirable casting method for rapid prototyping is a metal mold technique such as die casting, squeeze casting or permanent mold casting. In all of these cases, a metal mold needs to be fabricated rst. In the military, rapid tooling is needed when a product is under development or when relatively few parts are required to replace components in legacy weapon systems. It would strengthen and speed the supply chain to develop rapid, low-cost means of producing dies suitable for a limited number of die castings such as 5,000 pieces before serious thermal fatigue or other cracking occurred in the tooling. The objective of this project was to evaluate methods and materials that can potentially shorten the lead time and/or reduce the cost of rapid tooling used in die casting, squeeze casting and permanent mold casting. The dimensional characteristics and durability of the resulting tooling were also addressed. Approach: With few exceptions, most metal molds are fabricated from ferrous alloys. Tool steels in general and hot tool steels in particular are the most frequently used die materials for production die casting and squeeze casting inserts. Permanent molds are often cast in gray or ductile iron. The types of steels of interest in this study were H-13, H-11, or modied H-11, as well as some lower alloy, more economical, steels such as 4140, P20, and, for Figure 1. Direct Metal Deposition Process

very short runs, 1040, or high strength gray and ductile iron. The study evaluated and compared the following methods of rapid tooling fabrication: 1. Casting ductile iron rapid tooling in no-bake sand molds from oversized patterns produced from 3D CAD programs. 2. Investment casting rapid tooling in H-13 die steel from prototype wax patterns produced from a 3D CAD model. 3. Machining rapid tooling from a forged block that had been tempered to a lower hardness of 40-42 HRC. This method utilized Numerical Control (NC) machining from 3D CAD computer models of the tooling for rough and nish machining. The evaluation of the potential materials and fabrication processes included dimensional accuracy, surface condition and performance of the tooling. A key issue in selecting the material for rapid tooling is to ensure it will last long enough to make the required number of parts yet last no longer than necessary. To test the performance of candidate materials, the Thermal Fatigue Immersion test at CWRU was used to simulate the casting environment. This test has become a preferred and widely accepted method of screening die and mold materials. The standard procedure is to operate the test for 5,000 immersion cycles, measure the cracking pattern and follow this method for 10,000 and 15,000 total cycles. A more severe crack pattern indicates a lower thermal fatigue resistance of the tested material. The results of this test have correlated closely with the behavior of dies in industry. Results: Rapid tooling for permanent mold casting was made by casting ductile iron in no-bake molds with satisfactory results. While some machining was required to bring the critical dimensions of the cavity into the specied tolerance window, the lead time was still relatively short. When die casting inserts were investment cast from H-13 tool steel, the atness and dimensional accuracy were not acceptable. While machining of the cast inserts is an option, it would offset some of the advantages of net shape casting, especially the lead time. While machined rapid tooling can be made in very large sizes, cast rapid tooling is normally limited to smaller sizes. Complex rapid tooling can often be cast in a more cost effective way and with shorter lead times. However, the accuracy and surface nish of cast rapid tooling is not as good as machined rapid tooling. Fabrication of rapid tooling of tool steels by NC machining, directly from a CAD model provides the best combination

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Figure 2. P20 inserts produced in less than three weeks from a CAD model by Rapid Machining

Implementation Strategy: This project demonstrated that there are techniques which can be used to quickly provide tooling for prototype castings or even small production runs. These techniques open new opportunities for casting producers to enter new markets, where the long lead times required for conventional tooling prohibited their participation. In addition, these techniques offer the potential to reduce the lead time and cost of even conventional die casting, squeeze casting, or permanent mold tooling.
Monitoring Task Force: Die Materials Task Force Sponsored by: U.S. Department of Defense and NADCA This research is featured in more detail in the following transaction: T07-061

of lead time, performance and cost. Careful selection and heat treating of the insert material is essential. Recent advances in cutting tool technology allow high speed machining of quenched and tempered steels up to 4243 HRC hardness. Furthermore, Electro-Discharge Machining (EDM) can be performed on rapid tooling inserts of any hardness. These developments narrow the gap between rapid and production tooling. It is possible, as demonstrated by this study, to utilize modied H-11 steels in a pre-hardened condition, to fabricate rapid tooling that can last long enough to be used for production of large numbers of die castings, well beyond short runs. At the same time, if only a small number of castings are required, further savings in cost can be achieved by utilizing lower alloy, softer steels. In every case, the size and conguration of the part and the die design have to be carefully considered to avoid premature failure of the tooling.

For further information, contact: North American Die Casting Association 847.279.0001 phone 847.279.0002 fax www.diecasting.org/research research@diecasting.org

NORTH AMERICAN DIE CASTING ASSOCIATION

241 Holbrook Dr. Wheeling, IL 60090 Email: research@diecasting.org www.diecasting.org/research

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EFFECT OF DIE DESIGN ON THERMAL FATIGUE CRACKING OF DIES

J. Wallace & D. Schwam, Case Western Reserve University
Project Objectives: The thermal fatigue of steel die casting dies becomes more severe at higher operating service temperatures, reducing die life signicantly. Consequently, to extend die life, die design has to address efcient cooling methods. A key issue in this respect is the size and location of cooling lines relative to the surface of the die. This subject was studied in detail, to determine the effect of die temperature on thermal fatigue cracking of H13 dies. Approach: This investigation correlates the thermal fatigue cracking of die steel in an immersion test specimen with the die temperature attained near the surface and the corresponding softening of the steel. The effect of cooling line location versus the surface temperature and the resulting cracking pattern were determined for various immersion times and different sizes of cooling lines. The experiments involved testing three specimens for which the immersion time in the molten metal was the only variable. The maximum and minimum temperatures reached at the corner of the specimen and the temperature distribution inside the specimen (toward the cooling line) varied as a function of the time spent in the molten metal bath. The thermal fatigue behavior of the three specimens was compared with the reference specimen which had 9 seconds of immersion time. There is a clear trend for the thermal fatigue cracking parameters to increase with immersion time. Since the thermal fatigue test at CWRU has previously provided a remarkably accurate prediction of the relative thermal fatigue cracking, these results should have good applicability in die casting operations. Results: Higher die temperatures induce faster and deeper softening of the steel leading to more thermal fatigue damage. Die designs with cooling lines close to the die surface can reduce this damage signicantly. The results demonstrate that the higher the temperature, the more thermal fatigue damage will occur. Initially, the surface strain is within the elastic capabilities of the die steel. The surface of the specimen has irregularities in the form of corrosion pits or surface scratches. These sites serve as stress concentrations. Plastic deformation can therefore occur at stresses well below the yield strength of the parent material (it must be noted that the strength of the material drops at high temperature) and initiate fatigue cracks. In addition to the stress concentrations caused by surface imperfections, tempering weakens the surface material. A cumulative fatigue process occurs in the material, since plastic strain gradually increases during the test as a result of the lower yield strength of the material. The compressive stress will eventually exceed the elastic limit of the steel and plastic deformation will take place after the initial elastic strain has occurred. Under these conditions, it is therefore necessary for the material to drop below a certain strength level characterized by a lower hardness value in order for the crack to initiate. It has been experimentally demonstrated that if the strength properties of the material are reclaimed before the cracks are initiated; the thermal fatigue behavior can be markedly improved. This experiment consisted of cycling an H13 steel specimen for 2,500 cycles and then re-heat treating it to the original hardness value. It is clearly shown that re-heat treating the specimen to 51 HRC after every 2,500 cycles exhibits better resistance against heat checking. The cyclic heat treatment reclaimed the strength of the material and its resistance against cracking, impeding crack initiation, as well as the propagation of the existent cracks. The following three conclusions were drawn from the project: 1. For a conguration without severe stress concentrators, the softening of the steel is the most important factor for the crack initiation. Less thermal fatigue damage has been observed when the conditions promoted lower temperature at the surface, which preserved the hardness and hence the strength. A high value of yield strength means higher material resistance to plastic deformation. At the same time, elevated temperature at the surface will induce a deeper softening. It appears that a condition for the extension of the thermal fatigue cracking damage is the decrease in strength ahead of the crack front. 2. In die casting applications, the highest maximum temperature will occur in the thin sections where Figure 1. The Effect of Cooling Line Diameter on Average Maximum Crack Length

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the materials capacity to absorb and transfer the heat from the surface is very different. From another point of view, high temperature long resident time conditions are important, because of the similarity with die casting of large components, when the die is subjected to elevated temperature for longer periods of time. The experimental results have shown an important decrease of the cracking when the cooling line is positioned closer to the surface. Moreover, the experimental data indicates the existence of a temperature threshold, below which the thermal fatigue damage is minimal. A cooling line closer to the surface will shift the maximum temperature towards lower values, and at the same time, keep the stresses at a relative constant value. However, decreasing the maximum temperature at the surface by placing the cooling lines too close to the surface may be limited by the high level of hoop stresses that could be created at the cooling line. 3. The presence of strong carbide-former elements like chromium, molybdenum, and vanadium will reduce the softening by preserving a ne distribution of carbides. These elements inhibit the coarsening of cementite in the range of 400-700C. At the same time, these elements form ne carbides that are thermodynamically more stable than cementite. Among the three elements, chromium-rich carbide is the most susceptible to growth, but the presence of molybdenum and vanadium inhibits it to a certain extent.

Figure 2. Total Crack Area vs. Maximum Temperature at the Corner of 2x2x7 H13 Specimen for Different Immersion Times

Implementation Strategy: This project showed that softening of the steel by excessive die steel temperature is the most important factor for the initiation of cracks in the die surface. Both the use of larger cooling lines and moving the cooling line closer to the die surface are effective in reducing the maximum die surface temperature. Where possible, die casters can minimize heat checking of dies by managing the maximum die temperature. In addition, the presence of molybdenum and vanadium in the die steel allow cooling lines to be closer to the die surface.
Monitoring Task Force: Die Material Task Force Sponsored by: U. S. Department of Energy and NADCA This research is featured in more detail in the following transaction: T07-053

For further information, contact: North American Die Casting Association 847.279.0001 phone 847.279.0002 fax www.diecasting.org/research research@diecasting.org

NORTH AMERICAN DIE CASTING ASSOCIATION

241 Holbrook Dr. Wheeling, IL 60090 Email: research@diecasting.org www.diecasting.org/research

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RAPID TOOLING FOR FUNCTIONAL PROTOTYPING OF METAL MOLD PROCESSES

L. Ouimet, G. Ward, GM
Project Objectives: The goal of this project was to build, run and validate a mid-size transmission case die to prove out the Rapid Tooling-Rapid Machining technology and provide a new benchmark (16 weeks from design release) for prototyping medium to large die castings. Standard timing for a production die of this size is 46 to 52 weeks from release of data base to parts. Comparable timing for prototype sand castings was benchmarked at 12 weeks. Approach: Fast to Market is a major initiative for the Automotive Industry. GM Powertrains Transmission Engineering developed a master timing plan and determined that the transmission case castings were among the critical long lead time items which drove the current product lead time. Dissecting the problem further, the die casting die for the transmission case castings was one of the key drivers of lead time. A USCAR project Rapid Tooling for Prototyping Metal Mold Processes took on the problem of long die cast tooling lead time. The project investigated many technologies for generating the insert steel quickly and developed a generic holder block for large sized die castings. Utilizing rapid machining of prehardened H-13 steel technology and generic holder blocks, tooling lead time was cut by more than 50%. The part design was completed using Unigraphics version 11. A fully lleted 3D solid model was completed by a very experienced designer. Process simulation software was used to design the cooling system and metal injection system for the die. The die was built in 15 weeks from release of part data utilizing a generic holder block and rapid processed and machined pre-hardened tool steel inserts. Three thousand parts were made in six days with only minor process modications. Results: To achieve fast die cast prototypes, coordination of the following areas must be controlled by a cross-functional team: product design/analysis, tool design/analysis/build, process design/analysis, and a capable die casting manufacturer. Each of these areas is discussed in more detail below. Product Design. The product design time was not included in the project timing but it is the key enabler to fast lead-times. Many projects have been stalled or stopped with a poorly designed casting. Good design guidelines for die cast products and an experienced product designer with excellent CAD skills are a must for setting up a successful rapid tooling project. Poor designs can cause high scrap rates and major process startup/debug problems. Poor CAD model construction can cause delays in tool programming. Filleting has long been a major time element in the design. New CAD software revisions have eliminated many of these problems and have cut at least 4 weeks off the design process. A fully lleted 3D part solid model is needed. The product must be designed for both tool build and die casting. Early involvement of all parties allows part design consideration to be incorporated that will have a positive effect on project timing and casting quality for both prototype development as well as production. Tool Design. The design of the die was based around an existing generic holder block. The generic holder block is a common frame in which the part specic inserts are located and secured. This particular generic holder block was converted from a 3-slide to a 4-slide die conguration. The holder block is termed generic because it is designed with exibility in mind. Regular production holder blocks are built to be robust while being economical so they tend to be specic for each part. Utilizing a generic holder block reduces tooling lead time by 16-20 weeks over a conventional die build. With this generic holder block as a base, inserts were designed to produce the mid-size transmission case. Locator positions, gating position, and casting critical areas were all considered in the initial casting orientation along with whatever die set limitations there are. The part was fully dened using Unigraphics parametric solids. This allowed rapid denition of die inserts. Tooling models were developed for CAM programming. Programming was done as the die design was completed. Assembly prints were produced, rather than individual detail drawings, to speed up the total design time frame. This reduced the design time by 75% over standard design time. The lead tool maker was allowed exibility in the tool build, with the major criteria being die functioning rather than long run capability or replaceability as would be required in full production tooling. Three thousand castings was the criteria. Tool Build. The material was purchased, and immediately heat treated to 36-38 Rc. The normal procedure would be to rough machine, heat treat, and then nish machine. This alone saved about 4 to 6 weeks versus conventional production die procedures. Only the casting areas of the inserts were benched where necessary for part removal. Normally the entire insert surface is polished. Some EDM areas were not polished to eliminate the white layer which is inherent in the EDM process. This saved approximately 2 weeks. Final stress relief was not incorporated. This would normally take 3-4 days. Since the holder block was available from the start, inserts were t as operations were nished, assuring proper sizing, water line locations, screw locations and ejector pin locations, minimizing last minute problems.

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Process Design. This added step in the project stands out as being the most different from a standard die build. This activity was done concurrently with initial tool design so no additional project time was taken. Generally the die builder designs the die registration system, cooling systems, and metal injection system with help from the die caster, but with little or no knowledge of the parts functional requirements. The die caster sets the die up in a die cast machine with locking force and parameter capabilities based on past experience. The thrust of this project was to design the process based on knowledge of the functional requirements using process analysis software and NADCA process design equations. This added step saved 2 to 6 weeks in process set-up and debug. Capable Manufacturing. Even with all of the preparation for this project, attention to every manufacturing detail had to be met. For this reason, an experienced transmission case die caster was selected to make the parts. The die was set and initial samples were made. On one of the initial shots the bottom slide stuck. Clearance was added and the slide re-assembled. When restarted the casting stuck in the die. Some radii were increased in non-functional areas to strengthen the part. Once the radii were added the die began to run well. The parts looked good except for one area of poor ll. The analysis work was reviewed and conrmed this area to be the last to ll. Based on direction from the analysis, gates were opened, vents were added, and water was turned off. This initial development work took less than 2 full days. After these changes, the castings looked better and the decision was made to accept and continue to run. From that point the die ran consistently without interruption for the entire 3000 piece run.
Monitoring Task Force: NADCA Staff and Eppich Technologies Sponsored by: USAMP This research is featured in more detail in the following transaction. T99-121

For further information, contact: North American Die Casting Association 847.279.0001 phone 847.279.0002 fax www.diecasting.org/research research@diecasting.org

NORTH AMERICAN DIE CASTING ASSOCIATION

241 Holbrook Dr. Wheeling, IL 60090 Email: research@diecasting.org www.diecasting.org/research

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EXTENDING H13 DIE LIFE THROUGH HEAT TREAT OPTIMIZATION

John Wallace and David Schwam, Case Western Reserve University

Business Benefit: This project provides the die caster with information on extending die life and reducing thermal fatigue cracking. Project Objectives: The primary objective was to determine how the heat-treating of H13 die steel can optimize its useful life. Approach: Thermal fatigue test bars were cooled at various rates from the austenitizing temperature. These test bars were then cycled repeatedly into molten aluminum and then sprayed with die lubricant.
Total Crack Area ck 10 (pm5 )

Figure 1. Effect of Cooling Rate on Total Crack Area (Premium Grade H13 heat treated to 46-47 HRC).

Heat Treatment on Die Life

The Effect of Cooling Rate on Total Crack Area ( H13 46-47 HRC)
300 280 260 240 220 200 180 160 140

2x2x7 , WC7
Insulated/14F/min 1 bar/100 F/min 10 bar/200 F/min Oil/7250 F/min

1 bar insulated 10 bar

120 Results: The extensive studies conducted 100 on the heat treating behavior of premium 80 grade H13 steel have shown that the heat 60 treating process is at least as important as 40 the selection of the proper die steel in deter20 mining die life. The thermal fatigue cracking 0 is sharply reduced by using an austenitizing 0 temperature that will place the maximum amount of carbide forming alloys in solution in the austenite without reducing the toughness significantly.

oil

5000

10000

15000

Thermal Cycles

This quenching temperature for H13 is 1,900F, although it may be 1,875F for other die steels. Then, the die casting die should be cooled as rapidly as possible from the austenitizing temperature to help retain as many of these alloying elements in solution as feasible to reduce their tempering or softening tendency at the die surface. The die life can be extended by keeping the die surface as hard as possible in service. The influence of the high rate of cooling on the die life is shown in Figure 1. In this figure, the effect of the cooling rate from the austenitizing temperature on the total area of thermal fatigue cracks obtained for the immersion thermal fatigue test is shown. Although the thermal fatigue test is small and simple in design, compared to die casting dies, some of the advantages of the rapid cool from the austenitizing temperature can be obtained with dies by using an interrupted oil quenching treatment on the die.

The use of such a treatment is shown in Figure 2. In this case, a die insert of 14.6 by 7.9 by 7.75 inches was quenched from about 1,900F in oil for 9 minutes, pulled out into air to allow it to equalize in temperature and then reinserted in oil for cooling to 200F. This die was not cracked; it had a maximum amount of distortion of 0.030 inches. The cooling rate for the critical temperature required was 177F/min. This is fast enough to provide high resistance to thermal fatigue cracking. Figure 2. Interrupted Quench
(Die 14.6x 7.9x 7.75) -- Interrupted Oil Quench @ EHT

Temperature ( oF)

Core

out

in

Surface

Time (min)

Cooling Rate Measured by the Surface (1/8) Thermocouple at the Center of the Largest Face between 1750o F to 615o F is 177o F/min

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Implementation Strategy: The implementation plan should be to follow the NADCA Recommended Procedure for H13 Tool Steel, Item #229. This document specifies the heat treatment cycle including austenitizing temperature, minimum quench rate, and tempering temperatures, as well as material and heat treatment acceptance criteria. I

Monitoring Task Force: Die Materials Committee Sponsored by: U.S. Department of Energy and NADCA Additional resources: NADCA Transaction T99-102. Also, the results of this project have been incorporated in the NADCA Recommended Procedure for H13 Tool Steel, Publication Item #229 and the NADCA Care and Maintenance of Die Casting Dies Manual & Checklist, Publication Item #501.

For further information, contact:

North American Die Casting Association 847.279.0001 phone 847.279.0002 facsimile www.diecasting.org/research research@diecasting.org

North American Die Casting Association

241 Holbrook Drive Wheeling, IL 60090 Email: research@diecasting.org

www.diecasting.org/research

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RESIDUAL STRESS AND SOFTENING EFFECTS ON DIE LIFE

John Wallace and David Schwam, Case Western Reserve University

Business Benefit: This project provides the die caster with information on the benefits of rapid quenching to improve hardness on the die surface. Project Objectives: The primary objective was to determine what can be done to minimize the effects of high compression stresses that occur at the heated die surface in die casting. Approach: Thermal fatigue immersion tests were conducted to determine how the austenitizing temperature and the cooling rate from that temperature contribute to die steel life. Results: The thermal fatigue cracking of the die surface has been shown to be caused by upsetting of the die produced by the high compression stresses that occur at the heated die surface. This high temperature can produce a softening of the die surface from both the temperature and the high compressive stresses. The studies conducted on this project have shown how a rapid quench from the austenitizing temperature and tempering to a high hardness can reduce the softening that occurs. The plot of the decrease in hardness at the corners of the thermal fatigue immersion test conducted by this project shows how the decrease in hardness is substantially less for the test pieces cooled from the austenitizing temperature at 340F/minute in oil compared to the slower cool at 160F/min for the 5 bar nitrogen quench. The decrease in hardness is much greater for the slowly cooled specimen at 50F/minute in a one bar nitrogen quench. These results show why the rapid cooling from the austenitizing temperature increases the die life.

The residual stress on the surface of the die is usually compressive and additive to the applied thermal stress. When cracking occurs, the residual stress is relieved. The work conducted with applied known residual compressive and tensile stresses at the surface show somewhat reduced thermal fatigue cracking with residual tensile stress. I

Oil Quench 1875o F/49Rc

Cooling Rate 340o F/min

5 Bar Nitrogen 1875o F/44Rc Cooling Rate 160o F/min 1 Bar Nitrogen 1875o F/49Rc Cooling Rate 50o F/min

Softening of H13 Thermal Fatigue Samples After 15,000 Cycles Monitoring Task Force: Die Materials Committee Sponsored by: U.S. Department of Energy and NADCA

For further information, contact:

North American Die Casting Association 847.279.0001 phone 847.279.0002 facsimile www.diecasting.org/research research@diecasting.org

North American Die Casting Association

241 Holbrook Drive Wheeling, IL 60090 Email: research@diecasting.org

www.diecasting.org/research

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IMPACT ROUND ROBIN TESTING FOR H13 DIE STEEL

G. Brada, Bodycote Taussig, Inc.

Business Benefit: This project confirms the value of following the NADCA Recommended Procedures for H13 Tool Steel, eliminating the need for more costly testing. Project Objectives: The primary objective was to establish third-party industry specifications for the acceptance of premium quality H13 heat treated tool steel. The NADCA Recommended Procedures for H13 Tool Steel (NADCA Publication #207) has improved the quality of die cast tooling by providing the die casting industry with premium quality H13 steel acceptance criteria, a vacuum heat treatment procedures and proper welding procedures. The document only provides specific acceptance criteria for the starting, annealed H13 premium steel. The acceptance criteria for vacuum heat treatment have not been established for this procedure. Several individual die casting companies have established their own internal specifications for heat treatment acceptance, but it has been the goal of the NADCA Die Materials Committee to establish a third party industry specification for the acceptance of premium quality H13 heat treatment. Approach: This ambitious project was initiated to examine the effects of steel quality, heat treatment quench rate and Charpy v-notch impact test temperature on the microstructure and toughness of premium quality H13 tool steel. The project was based upon an experimental matrix consisting of four steel quality levels with three heats of steel for each quality level. Five quench rates were evaluated to examine the effects of heat treatment variables and the resulting heat-treated steel was subjected to Charpy v-notch impact testing at four different temperatures. Representative samples from each steel quality/heat treatment quench rate combination were subjected to microstructural evaluation. The die steel was supplied to the project as "in-kind" contributions from steel company members of the NADCA Die Materials Committee. Criteria for the steel to be included in the study was that the parent block be between 10 inches and 14 inches in thickness by at least 16 inches in width to provide material representative of the larger cross-sections utilized in the die cast tool building industry. Twenty coupons measuring approximately 1/2 inch by 2-3/16 inches by 4 inches were prepared from each block of steel. The coupons were cut from the center portion of the parent steel blocks where the 2-3/16 inch dimension of each coupon represented the short-transverse orientation. Commercial vacuum heat-treating members of the NADCA

Die Materials Committee provided heat treatment processing as "in-kind" contributions to the project. The test procedure consisted of tack welding four coupons of each steel quality capability level onto a master block measuring approximately 12 inches by 12 inches by 24 inches. Thus, a total of 40 coupons were attached to the master block prior to commercial heat treatment. The coupons were randomly tack-welded to the master block such that there were 10 coupons attached to each of the four 12 inch by 24 inch sides. This entire procedure was conducted four separate times, using different heat treaters to produce heat-treated coupons representing the four targeted cooling rates. The selected rates consisted of a slow air cool (<15F/minute), 50F/minute, 80F/minute and 120F/minute. Thermocouples were imbedded into the master block at various locations to measure the actual cooling rate during the vacuum quenching process. Each master block/coupon set was heat treated per the requirements of the current NADCA 207 recommended procedure with the exception of the cooling rate. The vacuum heat treatment furnaces were operated to produce the four targeted cooling rates. Following the controlled quenching process, the coupons were triple-tempered to produce a final hardness of 44/46 HRC and were submitted for Charpy v-notch impact testing. To investigate the possibility of increasing the ability of the test method to separate high toughness from low toughness material, the CVN testing of each combination of steel and heat treatment cooling rate was done at four test temperatures; room temperature, 200F, 350F and 500F. Results: The scope of this project resulted in a significant amount of data in the form of CVN impact toughness values and microstructures as a function of steel quality and heat treatment quench rate. There were more than 600 individual CVN specimens tested and 250 microstructure photos produced. Several conclusions can be drawn from the results of the project: 1. Conducting the CVN impact toughness tests at elevated temperatures did increase the measured toughness values. However, it did not significantly improve the ability of the test to separate high-toughness and low-toughness steels. The elevated temperature impact testing did not help to differentiate between heat treatment quench rates. The additional variables and costs associated with the elevated temperature impact test were determined to be undesirable as a standard NADCA test protocol. 2. A Charpy test methodology based upon testing five individual specimens and reporting the average results of three specimens after dropping the high and low values was found

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to significantly reduce the average standard deviation of CVN data. 3. The CVN impact toughness of premium quality H13 was found to increase with increasing quench rates. However, based upon the limited data resulting from this investigation, there is no clear justification for altering the current NADCA minimum recommended quench rate of 50F/minute. 4. The degree of intergranular carbide precipitation did not correlate with the impact toughness of commercially heattreated steel in the range of 50F/minute to 120F/minute quench rates.

Implementation Strategy: The results of this project confirm the value of following the NADCA Recommended Procedures for H13 Tool Steel, including the Charpy v-notch testing of H13 steel used for die casting dies and inserts. Even more costly testing of die steel samples was only marginally able to discriminate better than the current NADCA procedure. All die casters should adopt the NADCA procedure and monitor revisions to the procedure as they are published. I

Monitoring Task Force: Die Materials Task Force Sponsored by: NADCA

For further information, contact:

North American Die Casting Association 847.279.0001 phone 847.279.0002 facsimile www.diecasting.org/research research@diecasting.org

North American Die Casting Association

241 Holbrook Drive Wheeling, IL 60090 Email: research@diecasting.org

www.diecasting.org/research

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DIE MATERIALS FOR CRITICAL APPLICATIONS AND INCREASED PRODUCTION RATES

J. Wallace, D. Schwam and Q. Zhou, Case Western Reserve University

Business Benefit: This project provides the die caster with information on the use of die steels with improved thermal fatigue resistance, such as Dievar and QRO-90 that could improve cycle rates compared with H13 die steel. Project Objectives: A significant amount of testing has been conducted to determine the best composition and processing techniques for H13 steel used for die casting dies. Through these efforts, significant improvement has been made in the functional life of die casting dies. The purpose of this project was to study whether other types of die materials, such as nickel-based alloys and refractory metals, might provide increased resistance to failure by thermal fatigue cracking, which would permit them to be used in demanding applications or which would allow faster cycle rates than permitted by conventional H13 die steel. Approach: Tests were conducted on two types of candidate die materials. These included: new types of H13 and H11 die steels, and non-ferrous materials, including metal matrix composite and high-thermal conductivity alloys. The H13 and H11 samples were tested by immersion in molten aluminum at 1350F to determine the total crack area and the average maximum thermal fatigue crack length. The results showed that some of the materials behaved somewhat better than the control premium grade H13 processed by a fast quench and double temper. In addition, some of the more recently developed steels showed considerable improvement in thermal fatigue cracking and have changed the cracking mode from "corner cracks" to a "surface crack" behavior. Examples of this are QRO 90 and Dievar, which show mostly surface cracks. The surface cracking has very limited depth and does not appear to produce thermal fatigue cracking that subjects the metal to significant thermal fatigue damage. In an effort to determine the reasons for the improved behavior of these steels, additional experimental procedures were conducted. These procedures included: Determining the carbide count in the as-oil quenched condition with the MSQ Image Analysis System. Determining the softening at the thermal fatigue sample corner by microhardness testing after 5,000; 10,000; and 15,000 cycles. Computing the total corner crack area and the maximum crack length utilizing the MSQ Image Analysis System. The results of these tests showed that carbides are not as common in as-quenched Dievar, QRO-90 and TQ1 steels.

Steels with lower carbide content resist thermal fatigue cracking better. Steels that exhibit the best tempering resistance also exhibit the best resistance to cracking. The cracks in the H13 specimen cut through the corners of the specimen, whereas, the cracks in the Dievar and QRO-90 tests were very shallow and were only on one side of the corners with considerable improvement in thermal fatigue resistance. Testing of non-ferrous candidate materials included some refractory metals, nickel-rich and copper-rich materials, and metal matrix composite materials. The testing showed that all of these materials are more resistant to thermal cracking than H13. However, when the average maximum crack length is considered, some of these materials, such as the Nybril compositions, can be subject to an occasional long crack forming from the corners. While many of the copper and nickel alloys exhibit better thermal fatigue behavior than H13, these alloys can be subject to damage on the corners of the specimen. This damage occurs because of the high solubility of copper and nickel in the molten aluminum and can cause difficulty in their use as die materials. It should be noted that none of the refractory metals which were produced from tungsten or molybdenum show any tendency to thermal fatigue crack. A metal matrix composite made from Ti-6Al-4V with titanium carbide particles was tested as a die material. This metal was inferior to H13 in thermal fatigue resistance. It is considered as a good shot sleeve material for aluminum because of its good resistance to soldering and its low thermal conductivity. Some of the high thermal conductivity materials, such as Brush Alloy 3, have been used in shot blocks. The rate of cooling of the biscuit in this shotblock is substantially faster for this copper material than for conventional steels. High thermal conductivity materials including the refractory metals can be considered for the shotblock or other inserts in the die where faster cooling is desirable. Results: The results of this project indicate that some of the more recently developed steels exhibit better thermal fatigue resistance than H13, even when that steel is produced to premium grade specifications. The copper and nickel alloys are also more resistant to thermal fatigue cracking but are subject to solution of the sharp corners into the molten aluminum alloy. The refractory metals from tungsten or molybdenum are not subject to thermal fatigue cracking and offer the possibility of being inserted into the die at hot spot

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areas. Refractory metals do not undergo any visible type of thermal fatigue cracking or other problems, except for their high cost and susceptibility to cracking under the wrong circumstances. The use of high thermal conductivity die materials at critical locations is an excellent way to avoid difficulty at these locations. Implementation Strategy: Die casters should consider the use of die steels with improved thermal fatigue resistance,

such as Dievar and QRO-90. Refractory base molybdenum and tungsten alloys have excellent thermal fatigue resistance and should be considered for use in areas with high thermal stress. High conductivity materials such as Brush Alloy 3 facilitate rapid solidification of the surrounding metal and should be used to increase the production rate of die castings. I

Monitoring Task Force: Die Materials Task Force Sponsored by: U.S. Department of Energy and NADCA

For further information, contact:

North American Die Casting Association 847.279.0001 phone 847.279.0002 facsimile www.diecasting.org/research research@diecasting.org

North American Die Casting Association

241 Holbrook Drive Wheeling, IL 60090 Email: research@diecasting.org

www.diecasting.org/research

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THE EFFECT OF COOLING RATE ON THERMAL FATIGUE CRACKING AND IMPACT RESISTANCE OF PG H13 DIE MATERIAL
J. Wallace, D. Schwam and S. Birceanu, Case Western Reserve University

Business Benefit: This project provides the die caster with information on how to optimize the material properties of die steel by specifying more rapid cooling rates from the austenitizing temperature. Project Objectives: The main mechanism of die failure is thermal fatigue cracking. It has been shown in previous investigations that the thermal fatigue behavior depends on the initial mechanical properties of the material and their behavior with temperature. The ability of die steels to resist thermal fatigue cracking depends upon both their resistance to temperature and their ability to deform without cracking. These are the main properties that control the resistance to elastic and plastic strain. The microstructure that is obtained during austenitization and quenching of the die steel is the primary feature that determines the behavior and the cracking of the steel. For this reason, the cooling rate from the austenitizing temperature has an important effect on the cracking resistance of the die steels. The objective of this project was to quantify the effect of the cooling rate from the austenitizing temperature on the thermal fatigue cracking, microstructure and impact resistance of premium grade H13 die steel. Approach: A block of Premium Grade H13 was cut into eight thermal fatigue test specimens and 16 Charpy V-notch pieces. These specimens were then quenched at controlled cooling rates: about 14F/min, 100F/min, 200F/min, and 7,250F/min for the rapidly oil quenched material. The temperature range of 1,880 to 1,000F was used for the controlling cooling rates. A test specimen with thermocouples embedded at 3 inches from the top and 0.05 inches from the corner was used to control the cooling rates. After testing for the thermal fatigue behavior in the regular immersion thermal fatigue test, the crack propensity of the material was determined. The final operation on these specimens consisted of metallographic measurements of the steels at the critical edges of the specimens. The impact bars were fractured at room temperature. Results: The cracking susceptibility of this material was well related to the rate of cooling. The most rapid cooling presented the best results followed by the rates of cooling at 200, 100 and 14F/min. The metallographic tests clearly showed the effects of the rates of cooling on the transformation structures of the thermal fatigue specimens. The microstructure of these materials reflects the rate of cooling, with the final structure illustrating the advantages of rapid cooling from the austenitizing temperature. The impact results varied from an average of 6 ft.lb. at the slowest rate, 12.75 ft.lb. at 100F/min, 18 ft.lb. for the 200F/min and 23.75 ft.lb. for the rapidly quenched specimen.

The results can be summarized as follows: 1. The rate of cooling from the austenitizing temperature of 1,880F is a very important factor in providing the structure and properties needed to attain dies with an excellent resistance to thermal fatigue cracking. In this investigation, the rapid cooling rate from oil quenching provided the best properties, followed by the cooling rates of 200F/min and 100 F/min. Excessively slow cooling resulted in the lowest resistance to thermal fatigue cracking. 2. The structure from the rapid cooling resulted in a fine distribution of alloy carbides in the steel. The size of these carbides increases somewhat with the cooling rates of 200 100F/min. At the slowest cooling rate, a large number of carbides were present, particularly at the grain boundaries. 3. The results of the Charpy V-notch tests are related to the gross cracking behavior of the die steels. In this instance, for Premium Grade H13, the most rapid cooling rate provided the highest values (23.75 ft.lb. average). Intermediate impact results were obtained with cooling rates of 200 and 100F/min (18 and 12.75 ft.lb. average, respectively). The lowest impact results (6 ft.lb. average) were obtained for the slowest cooling rate, as shown in Table 1. TABLE 1. Charpy-V notch Results Average of 4 Bars
Specimen Oil 10 bar 1 bar Insulated Cooling Rate [F/min] 7250 200 100 14 Charpy-V notch Energy [ft.lb.] 23.75 18 12.75 6

Implementation Strategy: The die casting industry should optimize the material properties of die steel by specifying more rapid cooling rates from the austenitizing temperature. While consideration must be given to cracking and distortion during faster cooling of larger pieces of steel, all specimens of H13 have greater resistance to failure during service with the use of more rapid cooling rates. I

Monitoring Task Force: Die Materials Task Force Sponsored by: NADCA R&D Funds

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For further information, contact:

North American Die Casting Association 847.279.0001 phone 847.279.0002 facsimile www.diecasting.org/research research@diecasting.org

North American Die Casting Association

241 Holbrook Drive Wheeling, IL 60090 Email: research@diecasting.org

www.diecasting.org/research

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RAPID TOOLING FOR LOW VOLUME DIE CASTING

J. Wallace and D. Schwam, Case Western Reserve University

Business Benefit: This project provides designers and die casters with information to effectively use rapid tooling methods to generate new business opportunities for parts that might not otherwise be suitable for die casting due to short production runs or long lead times. Project Objectives: Rapid prototyping casting methods are often employed when a small number of cast parts are needed. The casting method of choice is dictated by the dimensional accuracy, mechanical properties and surface finish required of the parts. Sometimes the desirable casting method for rapid prototyping is a metal mold technique such as die casting, squeeze casting or permanent mold casting. In all of these cases, a metal mold needs to be fabricated first. In the military, rapid tooling is needed when a product is under development or when relatively few parts are required to replace components in legacy weapon systems. It would strengthen and speed the supply chain to develop rapid, low-cost means of producing dies suitable for a limited number of die castings such as 5,000 pieces before serious thermal fatigue or other cracking occurred in the tooling. The objective of this project was to evaluate methods and materials that can potentially shorten the lead time and/or reduce the cost of rapid tooling used in die casting, squeeze casting and permanent mold casting. The dimensional characteristics and durability of the resulting tooling were also addressed. Approach: With few exceptions, most metal molds are fabricated from ferrous alloys. Tool steels in general and hot tool steels in particular are the most frequently used die materials for production die casting and squeeze casting inserts. Permanent molds are often cast in gray or ductile iron. The types of steels of interest in this study were H-13, H-11, or modified H-11. In addition, the study evaluated some lower alloy, more economical steels such as 4140, P20, and, for very short runs, 1040, or high strength gray and ductile iron. The study evaluated and compared the following methods of rapid tooling fabrication: 1. Casting ductile iron rapid tooling in no-bake sand molds from oversized patterns produced from 3D CAD programs. 2. Investment casting rapid tooling in H-13 die steel from prototype wax patterns produced from a 3D CAD model. 3. Machining rapid tooling from a forged block that had been tempered to a lower hardness of 40-42 HRC. This method

utilized Numerical Control (NC) machining from 3D CAD computer models of the tooling for rough and finish machining. The evaluation of the potential materials and fabrication processes included dimensional accuracy, surface condition and performance of the tooling. A key issue in selecting the material for rapid tooling is ensuring it will last long enough to make the required number of parts, yet last no longer than necessary. To test the performance of candidate materials, the Thermal Fatigue Immersion test at CWRU was used to simulate the casting environment. This test has become a preferred and widely accepted method of screening die and mold materials. The standard procedure is to operate the test for 5,000 immersion cycles, measure the cracking pattern and follow this method for 10,000 and 15,000 total cycles. A more severe crack pattern indicates a lower thermal fatigue resistance of the tested material. The results of this test have correlated closely with the behavior of dies in industry. Results: Rapid tooling for permanent mold casting was made by casting ductile iron in no-bake molds with satisfactory results. While some machining was required to bring the critical dimensions of the cavity into the specified tolerance window, the lead time was still relatively short. When die casting inserts were investment cast from H-13 tool steel, the flatness and dimensional accuracy were not acceptable. While machining of the cast inserts is an option, it would offset some of the advantages of net shape casting, especially the lead time. While machined rapid tooling can be made in very large sizes, cast rapid tooling is normally limited to smaller sizes. Complex rapid tooling can often be cast in a more cost effective way and with shorter lead times. However, the accuracy and surface finish of cast rapid tooling is not as good as machined rapid tooling. Fabrication of rapid tooling of tool steels by NC machining, directly from a CAD model provides the best combination of lead time, performance and cost. Careful selection and heat treating of the insert material is essential. Recent advances in cutting tool technology allow high speed machining of quenched and tempered steels up to 42-43 HRC hardness. Furthermore, Electro-Discharge Machining (EDM) can be performed on rapid tooling inserts of any hardness. These developments narrow the gap between rapid and production tooling. It is possible, as demonstrated by this study, to utilize modified H-11 steels in a pre-hardened condition, to fabricate rapid tooling that can last long enough to be used for production of large numbers of die castings, well beyond short runs. At

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the same time, if only a small number of castings are required, further savings in cost can be achieved by utilizing lower alloy, softer steels. In every case, the size and configuration of the part and the die design have to be carefully considered to avoid premature failure of the tooling. Implementation Strategy: This project demonstrated that there are techniques which can be used to quickly provide tooling for prototype castings or even small production runs.

These techniques open new opportunities for casting producers to enter new markets, where the long lead times required for conventional tooling prohibited their participation. In addition, these techniques offer the potential to reduce the lead time and cost of even conventional die casting, squeeze casting, or permanent mold tooling. I

Monitoring Task Force: Die Materials Task Force Sponsored by: U.S. Department of Defense and NADCA

For further information, contact:

North American Die Casting Association 847.279.0001 phone 847.279.0002 facsimile www.diecasting.org/research research@diecasting.org

North American Die Casting Association

241 Holbrook Drive Wheeling, IL 60090 Email: research@diecasting.org

www.diecasting.org/research

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IMPROVED DESIGN, OPERATION AND DURABILITY OF SHOT SLEEVES

J. Wallace, D. Schwam and S. Birceanu, Case Western Reserve University

Business Benefit: This project provides the die caster with information on the use of coatings and other techniques to improve the operation of shot sleeves. These improvements could result in potential cost savings of up to 20% through improved quality, less downtime and reduced energy consumption. Project Objectives: The use of shot sleeves has been a considerable problem in die casting operations. This item has a history of warping and bending in the operation of the process. In addition, the shot sleeve experiences a serious problem involving the build up of sintered material and rapid erosion of the material under the pour hole. These problems can require the replacement of the shot sleeve entirely too frequently. The objective of this project was to study the build up and erosion of shot sleeves in an attempt to end the problem as it exists in the industry today. Approach: After a long period of time and considerable effort, a method was developed that offered the opportunity of solving the problem for better life in shot sleeves. This method of testing the shot sleeve and its operation consists of a 1,500 psi maximum pressure hydraulic cylinder, actuated by a 30HP electric motor, which moves a plunger rod and plunger tip in a shot sleeve. The components are mounted on two U-beams assembled on a 300 gallon hydraulic fluid tank by means of shock absorbers. The automated ladle takes aluminum alloy from the furnace and pours it through a funnel into the shot sleeve. The plunger tip pushes the molten metal out of the shot sleeve at a rate of 6 inches per second. The metal is directed back to the furnace by means of an insulated launder. This procedure is repeated numerous times, with 36 seconds required for each cycle. The aluminum alloy used in this project was A356 with regular composition of: 7% Si, 0.3% Mg and 0.2% Fe. During the operation of this equipment, the automatic ladle picks up the A356 molten aluminum alloy at a temperature of 1,250-1,350 F and pours it into the shot sleeve through the funnel. The plunger tip employed initially was water-cooled nitrided H13. The molten metal was applied at a rate of about 7 pounds per ladle. The initial testing was performed with a nitrided H13 shot sleeve. The thickness of the shot sleeve was first held to 0.5 inches to accelerate the failure of the shot sleeve. After 2500 cycles, the original nitrided H13 sleeve was replaced and sectioned longitudinally. This sectioning showed the adherence of aluminum on the nitrided shot sleeve after it had worn through the nitrided layer. Further testing was conducted using other

shot sleeves with an increased sleeve thickness of 0.75 inches. Other shot sleeves with H13 base material were also tested which had either a TiAlN PVD coating, an addition of Stellite #6 because of its known wear resistance, or a molybdenum coating applied throughout the sleeve. Results: The results of the various tests conducted during this project can be summarized as follows: It is evident that penetration of the sleeve material involved washout by dissolution of aluminum intermetallic material at the aluminum and steel interface and the diffusion of aluminum and iron across the interface. The damage that occurred to the original 0.5 inch thick nitrided H13 sleeve indicated that soldered aluminum alloy had adhered to the original steel interface. The depth of the damage to the coating was 0.17 inches. The PVD coating of TiAlN on the inside surface of a nitrided H13 sleeve had a thickness of about 10 microns and was placed directly on the surface that was damaged, by a commercial coating supplier. This material was excellent until it wore through the 10 micron thickness. After that, the material behavior was similar to the nitrided H13. The Stellite #6 alloy was tested as a welded insert. Some difficulty developed welding directly on the surface of the sleeve and that forced the use of a separate plug on the surface. The welded insert was placed into a hole that was cut into the bottom of the shot sleeve directly below the pour hole. The composition of the Stellite #6 was: Cr 28.5%, W 4.5%, Co 60%, Fe 2%, Ni 2%, C 1%, Si 1%. It performed very poorly because of the solubility of the cobalt in the liquid aluminum. The molybdenum coating was applied over the entire surface of the shot sleeve, which was near the pour hole, to a depth of 250 microns or 0.01 inches. The plunger tip used for this experiment was made from Be-Cu alloy instead of nitrided H13 and was cooled by water. The reason for the use of a Be-Cu plunger tip is that the molybdenum coating is softer than nitrided H13 and a softer plunger tip is designed to avoid additional damage. This material held up the best of any material, and finally wore off in sections as the bond started to fail. With more experience, it is evident that molybdenum coatings could be a very good addition. Implementation Strategy: Based upon the results of this project, the following conclusions and recommendations are made: The molybdenum coating was the very best material for avoiding damage to the shot sleeve steel. The molybdenum held up longer than any other material. With an improved

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bond, the molybdenum coating would have lasted for a longer period of time. Additional experience with the application and use of molybdenum coatings in shot sleeves could provide significant improvement in shot sleeve performance. The nitrided coating of the H13 sleeve material provided some assistance to withstanding the wearing and soldering effect. The hard coating (TiAlN PVD) performed in an excellent manner as long as the coating was maintained. However, its thickness was limited to about 10 microns. After this coating wore off, the behavior was similar to that of the nitrided H13. The Stellite #6 material showed considerable wear under the action of the molten aluminum alloy with cracking occurring in Location of Cut-Out Under Pour Hole Where the Stellite Insert was Welded

the weldment. This wear is the result of the solubility of cobalt in the molten aluminum and shot sleeves are not an appropriate application for this material. The improved operation of shot sleeves will save a lot of energy and reduce downtime in the die casting operation. By reducing the lost energy and producing better die castings, the cost and energy consumed during die casting will be greatly reduced. It is estimated that the improvement in shot sleeve design and operation could reduce the energy required for die casting by 20%. I

Monitoring Task Force: Die Materials Task Force Sponsored by: U.S. Department of Energy and NADCA

For further information, contact:

North American Die Casting Association 847.279.0001 phone 847.279.0002 facsimile www.diecasting.org/research research@diecasting.org

North American Die Casting Association

241 Holbrook Drive Wheeling, IL 60090 Email: research@diecasting.org

www.diecasting.org/research

Turn Research into Action Business Solutions Based on NADCA Research

For further information, contact:

North American Die Casting Association 847.279.0001 phone 847.279.0002 facsimile www.diecasting.org/research research@diecasting.org

North American Die Casting Association

241 Holbrook Drive Wheeling, IL 60090 Email: research@diecasting.org

www.diecasting.org/research

Turn Research into Action Business Solutions Based on NADCA Research