No money, No time.  This is the dilemma that faces die casters everyday. The money to perform preventative maintenance is there but because of production demands, there is no time to do it.  Or, production demands are down, so there is no money in the budget for preventative maintenance.

Extending tool life and improving performance to remain globally competitive is now a constant uphill battle for US die casters. Badger is committed to seeing the die casting industry in the US survive and feel we can address both of these issues.  Plus what recently has been discovered, makes it even more critical to proactively keep your tooling in a healthy condition. 

For years and after countless papers on die fatigue, breakout has always been accepted

 to be associated with heat checking.

Lamination problems have been thought to be due to uneven degrees of solidification, porosity, and poor fill.

All of this is about to change.

In this newsletter we will illustrate for you another failure mode that is seen and has been studied extensively in fluid hydraulic systems.  This failure mode applies to die casting dies for molten metal as well but, to date, not much attention has been paid it. NADCA, however, does list it as one of the modes for die failure.

Click on the side bar buttons in the left hand column to become more informed on cavitation effect and how it is shortening your tool life.

Badger is so convinced that we are addressing a key cause for breakout, that we are prepared to guarantee our process. That takes care of the No money issue.

To address the production issue, we are recommending that the tooling be processed not after sampling but before ANY molten metal hits the surface.  That solves the No time issue.

Also realizing that sometimes changes need to be made prior to production, we are offering to reprocess the tooling NO Charge or for significantly less cost depending on the degree of modifications made prior to production.

There is research that shows that the tensile stresses in tooling build very rapidly.  So if you wait until sampling to do MetaLLife,

damage has probably already started due to cavitation effect, thermal fatigue,  and/or surface changes.

Prior to sampling, it is also easier to get preventative maintenance performed.  We see everyday, how a sample approved die will immediately begin running production and continues to do so until it fails, or stops producing acceptable castings.  The die is then pulled for a costly repair or each casting has to be reworked to be accepted which also adds unplanned cost. At this point, it is sometimes not possible for us to successfully close, with our MetaLLife, process, the larger cracks or replace missing metal that is broken out or pitted. 

Also by doing it prior to sampling or after engineering changes, we solve the issue of extra cost to again tear down the die.

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