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Extends Tool Life
Since 1983,
Badger Metal Tech, Inc. has had over 100,000 tools passed through our facility.
Thermal fatigue, soldering, breakout, gross cracking, and erosion are common failure modes
reactively witnessed or proactively anticipated by our customers in the die
casting tooling industry.
Thermal fatigue
is due to the constant expansion and cooling of the die casting die's
surface when molten metal is introduced into the mold. Over time, high
tensile stresses develop that want to pull the surface of the die apart.
This occurs first in high stress areas, such as radii, and sharp corners.
Limit this expansion and contraction, and you limit the thermal fatigue
factor and tendency for the die to pull apart.
MetaLLife
creates a high beneficial compression to the die's surface which is the
opposite of destructive tensile stresses. This increases the fatigue
resistance of the die which counters tensile stress build up. Dies
that cast high temperature molten metals such as: magnesium, aluminum,
and brass encounter thermal fatigue more rapidly than lower pour melt
metals. It is not unusual to see mild heat checking (thermal fatigue)
in such dies after only 10,000 shots. Zinc die casting dies, because of their
much lower pour temperature (about 900 degrees F) are not as prone to this
type of failure, however, do experience pitting from cavitation effect.
Not all cracking can
be prevented, however, when performed on NEW tooling in a structured
preventive maintenance program, the cracking is
stopped before it starts.
MetaLLife creates a
plastic flow phenomena which closes minor cracking and stop
the propagation of larger cracks in USED tooling. It is known physics
that a crack cannot propagate into or through a layer of compression unless
the fatigue level of the metal is exceeded. By closing clean minor cracks
with plastic flow compression, and inducing compression at the ends of
larger cracks, propagation of the crack is stopped. The longevity of
the crack closure is dependent on having a clean crack with no soldered
aluminum present.
Related Topics
> - Increases Fatigue
Strength |
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@ 72,000 shots - not processed
MetaLLife when
new and at 50K.
Casting from the die with 112,000 shots
@ 6,000 shots - not processed
MetaLLife
when new and at every 50K
Casting from die after 400,000 shots
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