north american die casting association – 113 th metalcasting congress april 7-10, 2009 las vegas,...
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North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
4 Success Stories T09-074
Jerald (Jerry) V. Skoff - Founder
Badger Metal Tech, Inc.
Benefits of Compressive Stress
Surface Engineering
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
Fill Problem - FiveStar
Case C0987 MN – 2008 – Bake Pan
FiveStar
Blistering in cosmetic area of brownie pan
Teflon coating adhesion problem
40 parts scrapped in 10 hour shift
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
Solution to Fill - FiveStar
FiveStarCompressive Stress processing
T41 – 5-6C Almen – 460 media
10A - .011
3A – GB
Cover and Ejector plus Gate
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
FiveStar - Photo
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
Five Star - ROI Benefits
FiveStarLaminar fill disappeared
Blistering stoppedMetal flow improved
Scrap dropped from 40 to 2 castings/10 hr shift
95% reduction
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
Heat Checking Problem - Kirby
Case C0082 TX – 2008 – Vacuum CleanerKirby
Non cosmetic&
Cosmetic6-7 components
30-35K Heat check would start on new tooling
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
Solution to Heat Checking - Kirby
KirbyCompressive Stress processingT41 – 5-6C Almen – 460 media
10A - .0113A – GB
Entire cast area of cosmetic side/sides
New tooling with polished castings
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
Kirby - Photos
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
ROI Benefits - KirbyKirby
No heat checking until 93K shots3x 200% increase (30-35K before)Better castings, easier to polishNo hidden porosity or inclusions
Begin doing on all dies includingauto finish high buff castings
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
Shortened tool life problem - Toro
Case C0266 – MN – Mower Decks
Toro
Thick wall castings – 150K life
Gate velocity 120-130 ft/sec
Good SPC
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
Toro - Photos
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
ToroCompressive Stress Processing
T40H – 8-9C Almen – 460 media4A – GB
Entire cast areas – cosmeticAlso some inserts that soldered received
PM program every seasonIn place for 18 years
Solution to short tool life - Toro
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
ROI Benefits - ToroToro
Reduced casting defectsLess die welding
Scrap rate reductionImproved flowPaint adhesion
Large return on investmentfrom 150K to increase of 370K+ (+146%)
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
Find effective PM program - Lamar
AluminumC0670 – CA Lamar Die Casting
Vendo – vending machine partsBefore 180K for Vendo Gauge Bar & Gate
380 aluminum
Bronwite - BrassWeather-Tec – impact sprinkler heads
Before 100,000 parts (8 cav) Weathertec(1550 [1625] degree F Bronwite metal)
CC99750 (brass 60% Cu, 20% Mn)
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
Lamar - Photo
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
Solution to PM Search - Lamar
LamarVendo Gauge Bar & Gate - (75K, every 100K)
High Production – 520K/yr180K to 420K Avg each die (+133%)
Weather-Tec Sprinkler HeadHigh production
From 100K to 200K+ – Still producing parts
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
More Case Studies 1986-2009
• Breakout & Pitting from cavitation effect C0027, C0258, C0376, C0834, C0542, etc.• Heat Checking – C0001, C0870, C0753, C0321 • Soldering – C0704, C0670, C0481• Porosity - C0274, C0693, C0150• Flow Problems – C0031, C0025, C0609• Laminar Fill – C0274, C0310
www.badgermetal.com/field-ml.htmwww.badgermetal.com/field-tl.htm
North American Die Casting Association – 113th Metalcasting CongressApril 7-10, 2009 Las Vegas, NV USA
AFS NADCA
Case Studies