You will find these buttons on the top of every page of our web site.
Use them to quickly navigate or return home if you lose your way - scroll each page as needed.
|
|
:
Letters - Over 100,000 dies processed
since 1983.
| ||||||||||||||||||||||||||
 |
Reduced die casting pressure - testimonial letter |
|
|
Less sticking soldering and drag of die casting |
|
|
Improved magnesium flow |
|
|
Reduced buffing and polishing time of casting (#857 03/13/01) |
Field Result
Comments - Preceding # is internal ref number for
customer.
(Our customer comments are
coded to protect our clients security)
Testimonial Letters - Preceding # is internal ref number for customer.
#299 - MN - The customer told us that after using our process for some time
he decided to try using it on a die that was giving him fits with filling.
Besides the filling problem disappearing, there was no soldering, no cracks in
the casting, and no flashing as before. He was also able to reduce his casting
pressure by 30%. The casting also looked much better with a reduction in flow
marks. Here is the customer's follow-up letter that we received:
Dear Badger Metal:
This letter is being sent to you in regards to the results of your
MetaLL
ifeÒ
treatment you applied to our mold that produces bracket , part #505-297.
Enclosed:
1. One part as cast with runner and spills attached
2. One part marked B (For before
MetaLL
ifeÒ)
machine pressure to fill 1500 PSI.
3. One part marked A-(After
MetaLL
ifeÒ)
machine pressure to fill 1050 PSI.
The
MetaLL
ifeÒ
process has allowed us to use a much lower pressure to fill the bracket.
The mold is parted with 3 cam pulls. Lower pressure has allowed us to run this
mold 2000 shots before pulling the tool and cleaning cam slides. With the higher
pressure we could run the mold only 200 shots before pulling the tool and
cleaning flash from cam slides.
Once again,
MetaLL
ifeÒ
Process has enabled us to increase production on this mold and many others you
have done for us in the past. Thank you once again Badger Metal Tech, and thank
you
MetaLL
ifeÒ.
Sincerely,
Tom Dousette - Vice President #299
Tom went on to tell us that the World Cup Sailing Teams now use a Shark Skin
finish on the hulls of all of their boats to increase their speed. He feels that
this same type of finish obtained from
MetaLL
ifeÒ
allows him to improve his casting process capabilities. We know that a
MetaLL
ifeÒ
surface improves the flow and reduces porosity concentration. We have not,
however, investigated how reduced die pressures would assist in even further
increases in tool life. Not as yet we haven't.....
Less sticking, soldering, and drag
#481 - AR - Very pleased with performance of tooling for parking meters that
we did for him. Dies no longer stick, solder, or drag. Also noticed that the
heat checking on the older tools is considerably reduced with much better
casting appearance. Flow is also improved. Plans on continuing to send us
tooling as soon as production schedules free up. So impressed were they that he
sent us a LETTER praising our process and service received. Quoted as follows:
"We have recently procured the services of
Badger Metal to do maintenance work on three (3) of our dies. Most specifically,
the cleaning of these dies and the
MetaLL
ifeÒ
process provided by Badger. I would like to take this opportunity to express the
highest of praise to Badger Metal for the excellent services and outstanding
quality of workmanship they provided to #481 Incorporated. Turn around time
between shipment for maintenance on the dies until the time they were resumed to
us, finished; was swift and very much appreciated by all concerned (our need to
have these dies in-house is always a concern).
I was very impressed as well as 100% satisfied with every aspect of the services
that we received from Badger. I look forward to our future business dealings
with Jerry and would highly recommend Badgers' services to any potentially
interested customer."
Charlie #481
Manufacturing Plant Manager
Improved magnesium and aluminum metal flow
#31 - IL - A problem of flow due to the configuration of the casting and
tool was preventing good fill. The problem was eliminated after topography
modification with a special
MetaLL ifeÒ
process.
#25 - KY - After seeing immediate improvement in the performance of a
large magnesium die casting die and its flow characteristics, this firm sent by
fax the following comments thanking us for a job well done:
Dear Mr. Skoff,
"I would like to congratulate you and your entire staff for a job well done. The
dedication to completing the work on the instrument panel cavities on such short
notice have proven Badger to be a "World Class Supplier". Thank you for your
efforts."
Sincerely,
Dave #25
Tool Engineer
Reduced time of buffing operations
#0857 - IA - Received via email
Paul,
MetaLL
ifeÒ
has been an excellent answer for us. It has eliminated many buffing
operations, and increased my die life. Thanks for all your help. Early
this summer you will see more new cavities.
Erik Hansen #0857
V.P. Manufacturing
#274 - WI - After applying MetaLL ifeÒ to a small barber utility tool, we were notified by our polisher that the casting was taking less time to buff due to a reduction in hidden porosity and better casting fill and surface characteristics. The cosmetic requirement of this tool was such that the slightest imperfection in the surface would show after painting which was unacceptable. MetaLL ifeÒ got rid of this concern.
#870 - CA - We use MetaLL ifeÒ on small brass dies sprinkler head die casting dies. Successfully have repeated the process on both NEW and USED versions of these multiple cavity tools to stop/close existing heat checking. Continued life extension improvement by adding this process to tooling. We and our end user sees improved parts with less heat checking.
#670 - CA - Use on brass dies and see major improvements in life and performance on these tools. Now starting to use on Aluminum dies for same reasons.
#626 - FL - Dies we processed for were previously running brass parts and had extreme amounts of heat checking. After processing, the dies looked so good we used these same tools to run zinc parts. Appearance of the zinc casting is quite acceptable for our product. #626 is a captive house.
Improved Performance & Extended Life
#792 - IN - At 70,000 shots after a MetaLL ifeÒ treatment on ejector side, and MetaLL ifeÒ + TherMaLLifeÒ on the cover side, the die continues to perform and has already out lasted the normal life cycle where they would begin to have down time for repairs and polishing to remove solder buildup.
#872 - IL - This customer has been able to increase their tool life for a sensitive automotive part ten (10x) fold by applying followed by TherMaLLifeÒ after final sampling on NEW tooling.
#150 - MN - Dies are running extremely well, however, before MetaLL ifeÒ their production manager said the dies could not be used anymore and would have to be retooled due to excessive casting leakage problems, and sticking with soldering. Casting appearance has tremendously improved.
#576 - PA - We definitely helped extend the life on the OLD bowl die. Customer and end user are pleased. Will continue to do more tooling.
#569 - KY- Very pleased with the transmission die we did (2 cavity). Said die is running and has not stuck or broke a pin. Customer now wants to do Cav #3,4.
#415 - IL - Have seen significant improvement in die performance since starting to use MetaLL ifeÒ. We plan to use MetaLL ifeÒ on all of his tooling in the future.
#691- CANADA - The die ran great. Before we did MetaLL ifeÒ, the die was totally unusable. Afterwards, we were able to run the die 19-20hrs/day 7 days a week with no problems. The die ran so well that we got 3 weeks ahead on production requirements. Now he will look at other tooling to do.
#039 - AR - We have set up a schedule to do MetaLL ifeÒ on all of their BIG runner dies every 30,000 shots. Seeing considerable benefit to casting appearance by incorporating MetaLL ifeÒ as a schedule maintenance procedure.
#590 - FL - The first scale housing (#1786) ran much better. Castings required much less rework. Also appeared to be some improvement in the flow characteristics.
#150 - MN - Customer continues to be pleased with results of doing the cattle tagger dies. Prior to our processing these dies he and his customer thought that new tooling might be necessary. This is no longer the case since the dies are holding up extremely well.
#659 - AR- Did a zinc die that had been welded and was not buffing out well. We did T-21 which gave them a 60Rms finish before buffing. The parts buffed out much better than before. Customer is very satisfied.
#150 - MN - said the cattle tagger die we did in May is doing exceptionally well after 3 runs. Their customer is pleased that he did not have to buy a new tool which was the altemative that was being considered if he had not found MetaLL ifeÒ.
#704 - CA - Vendo die is running better than ever after MetaLL ifeÒ. Shot rate has increased from 125/hr to 130/hr. Castings look great with a low reject rate of .05%. Considering for other high run tooling.
#609 - TX - The last DET 38 endbell (new die) we did in Nov 95 has been running since Dec 95 at a rate of 1K/day and now has about 40 weeks of run time = 200K shots on it with still no heat checking. Have noticed vast improvement in casting appearance and flow characteristics.
#032 - Toby Parks TX - New tooling for air conditioner component casting would heat check after only 5,000 to 10,000 shots. After MetaLL ifeÒ no heat checking in this time frame.
#753 - CA - The PR3 handle that he wanted to improve appearance if possible 50%, looked so good (at least 90% improvement) that he is going to send us an after casting that we can use in our advertising if desired. We have made believers out of the other owners of the company. For the future will consider MetaLL ifeÒ instead of building new tooling.
#039 - AR - Primary reason for doing MetaLL ifeÒ is to benefit from longer runs with less downtime and tool repair from heat checking. Cost of MetaLL ifeÒ pays for itself by this factor alone. They schedule redoing MetaLL ifeÒ at every 30,000 shots, scheduling permitting.
#321 - CA - The recent chair die mold that we did (both cover and ejector) is running much better parts with no signs of heat checking mirrored on the part. The die shows that the cracks are closed. Very satisfied. Sending more castings to quote.
#674 OH - Ran the first set of covers we did for one week with no problems and cracks stayed closed. Also the die seemed to hold lubricant much better. Pleased and now wants to do the ejector sides.
#542 - IN - says that the previous spider die would only get about 10,000 shots before it starting to heat check all over. Since doing MetaLL ifeÒ to a new set of cavities, now has 30,000 with no heat checking. We processed this too when the die was new after about 3500 shots.
#705 - MEXICO - The first iron sole plate dies we did now have about 20,000 shots on them with no new heat checking. Patrick is pleased with the performance of the tool and plans to do it again once he reaches 50,000 shots.
#760 - CA - Cosmetic appearance is one of the key selling features of their vacuum cleaners. Heat checking on the die requires costly secondary operations. MetaLL ifeÒ closed up the heat checks and allowed the tool to produce the necessary quality castings which reduced the customer's secondary costs.
Soldering using MetaLL ifeÒ or (MetaLL ifeÒ + TherMaLLifeÒ)
#704 - CA - The combination of MetaLL ifeÒ (T-41) + TherMaLLifeÒ reduces or eliminates soldering problems. Cores tested had an established history of soldering immediately after only a few shots or while the die was being sampled. Now they are able to run over 1000 shots without any soldering or indication of breakdown of the coating. Have processed both small (1/2" to 5/8" dia) and large (3" dia) cores with equal success.
#042 - MO - The customer eliminated solder problems on Allied Signal cores that normally would experience build-up after only approximately 900 shots. Two sets of cores were MetaLL ifeÒ + CrN coated (processed T-21 & T-41). Cores now have 15,000 shots with still no solder or build-up. It is interesting to note that during one of the production runs that the water was accidently shut off to the cores, however, the resulting build-up was minor and cleaned itself when the water was turned back on and lubricant reapplied to the die.
#054 - IL - Two cores were processed with T-41 MetaLL ifeÒ. These cores would historically solder between 12,000 to 13,000 shots. These same cores are now at 55,000 shots without any soldering. The two cores (2.75" dia x 6.2") were processed in May 1996.
#032 - Toby Parks TX -New tool sticking was always a problem on CFN cores because they have a zero to 1/2 degree draft. Would need to polish in draft to try and prevent this from occurring. After MetaLL ifeÒ with our T-21 process, their initiation stick problems dropped from 100% to 0%. Have since expanded use to inserts as well as more CFN cores.
#670 - CA - The 3500 Pelco dies are now running after MetaLL ifeÒ without any soldering problems. This die because of the protruding ear always soldered. Die cast machine operators are extremely pleased with this problem being eliminated. Same results on the Vendo Uni-Gage dies we recently did...No more solder problems.
#406- Ray Meyers OH - Still using the cores we did. Before he was having to change the cores twice per week. Now he runs about 8 weeks without touching them. He prefers the MetaLL ifeÒ and will be sending us more heat treated ones as soon as he has some.
#719- CA - (ZINC) impressed with the performance of the core pins we did. Not only did they not solder, but they also has a condition in the die which stressed the pins but only damaged the untreated pins. The MetaLL ifeÒ ones did not show as much damage. Also the first 2 weeks after our pins were installed, the die ran phenomenally well with no soldering.
#032 - Toby Parks TX - His customer is "tickled pink" with our T-41 process that we did on their ejector cores. Much less expensive than going with an acid etch according to Toby. Also running with much less problems. Has more to send to us.
#710 - OH - First parts are looking good on the small zinc "Z" fitting. Parts are not sticking as before.
#664- CA- The heatsink die we did for him earlier this month is turning our much better parts. No more sticking in the fin areas. Also pleased with the way the heat checks are closed. Casting has a much better appearance. Appreciated our quick turn around service (Accelerated Delivery) he requested.
#671 - CO - Have been using the process since August 1990 and would not think of running any of my tooling, whether NEW or USED, without first putting MetaLL ifeÒ on the dies before I do any coating. Currently we use the Futura coating (Titanium Aluminum Nitride - TiAlN).
#001- Wl - Kevin said that the blower housing after MetaLL ifeÒ eliminated a second operation for cleaning up the gate area which prior to MetaLL ifeÒ posed a handling problem. Very pleased with both physical appearance of casting and how long the improved condition has lasted. Also said that boat motor dies are working so well that this is the first time they have not had to weld them. Usually every 5K shots they are welding the fin area. They have done 3-4 sets of these tools with MetaLL ifeÒ and all are performing equally well. Try to do every 20K shots. Die performance, life, and casting appearance has improved considerably.
#001 - Wl - The boat motor die that we have repeatedly processed with MetaLL ifeÒ has made it through a complete production run without any welding required on the die. According to this customer, this is the first time that they have ever been able to run this tool for a full production run without having to weld the tool
Reduction in Porosity Problems
#693- OR - Is an end user of die castings. Since we did our gearbox lid and housing, we have noticed a tremendous improvement in the casting appearance with less porosity and pitting problems.
#30 - OH - The used transmission slides we did worked out well that they got the additional life they needed from this die before replacing with a new tool. Now considering doing on their new tool.
 |
 |
 |
|
|
#91 - IL - Applied to CPM10V draw cap. At most would get about 60K before tool would gall and have to be polished or replaced. Applied first the MetaLL ifeÒ process and followed this with Balzers TiCN coating. Micro pockets were questioned upon return to the customer with concern about these causing more problems than they already had experienced. Customer was assured and tool was installed and ran 4,000,000+ parts. Engineer has since left the company and is using MetaLL ifeÒ at his new employment facility.
#498 - WI - has been enjoying the MetaLL ifeÒ benefits since the late 80’s when their toolroom manager came across an ad in a leading trade journal. They performed a trial in 1987, on a high volume draw and pinch trimmed part and witnessed their "parts till polish" increase from 10,000 to 80,000 pieces. John Matteson now regularly use the process on all draw rings. When necessary, they can polish three to four times without having to retreat their tooling using a 600 abrasive paper and light oil. For severe applications, such as brushed #304 stainless, he uses it as a substrate preparation for an additional TiCN coating since they know MetaLL ifeÒ will not peel or chip.
#528 - Wl - Customer called back to say that the
MetaLL
ifeÒ
solved his galling problems when forming 1/8" stainless. Extremely pleased with
results.
#935 - IL - Uses on D2 and CPM tooling to reduce scoring of the produced
parts.
MetaLL ifeÒ allows
them to run over 6000 pieces as opposed to only a few before galling and
scoring of both the die and part would occur.
#680 - OH - Ran complete job of 38,000 parts with no galling or build-up on die. Now in the process of redoing all their tooling with MetaLL ifeÒ v/s chrome plating.
#680 - OH - So far has run 18,000 draw parts on a die that prior to MetaLL ifeÒ was impossible to run as little as 200-300 parts without galling up. Parts are better than he has ever seen off this tool. Had been using chrome plating with no success. 'Very, very, pleased." Saved him from losing us customer.
#669 - NJ - The set of rectangular draw dies that will did now have run 60,000 pcs with no pick up problems of any kind. Prior to our process, they were having problems with galling and pickup on the comers.
#788 - IL- Our customer is getting their best runs ever they have ever had with the draw ring we processed for their application.
#213 - OH - The lower form die we did went from 30K to 200K parts before any redress. Overall this resulted in over a 200% life improvement.
Blanking, Punching and
Perishable Cutting Tools
#46 - WI - A large stamping ring was picking up and galling after only a few strokes. After processing this problem has disappeared except for one small area where they had inadvertently polished the die. MetaLL ifeÒ was reapplied to the area and the die runs without problems.
#099 - WI - Was having their hobs coated. Started to have a problem with chipping of the edge when resharpening and during use. Now enjoy all of the MetaLL ifeÒ life extending and fatigue resistance benefits of coatings plus the added cost saving extra of not having to recoat when the hobs need to be resharpened.
 |
 |
 |
 |
 |
|
#922 - WI - Uses MetaLL ifeÒ on dies for blanking automotive and water heater parts in both compound and progressive configurations. Customer says the treated punches run about 30% longer with much less downtime. They also like how re-sharpenings can be done without removing the improved fatigue resistant benefits.
#661 - NY - The worm roll dies we did got 4600 parts before they chipped. Normally they expect around 1700-2000 pcs before chipping occurs. He also said that even the astounding 4600 piece figure was not a fair test because the machine these were used on had bearing problems. Had it not been for this problem the MetaLL ifeÒ worm roll dies would have gotten even more than 4600 pcs.
 |
 |
 |
|
|
#680 - OH - Customer has been using the MetaLL ifeÒ process for over 10 year on their progressive blanking and piercing tooling. The problems they had with chipping on their punches and dies when used on martin site material just disappeared once MetaLL ifeÒ was tried.
#063 - MN -The CPM M4 and D2 punches that we have been doing for him since 1989 are resisting fatigue edge cracking and chipping allowing longer runs. They are using these to stamp out 303 stainless steel parts for the medical industry. Nothing else he has tried works like the Metlife T-10 process.
Last Modified - Wednesday September 10, 2008 |
