Die Casting Die Thermal Fatigue and surface heat checking, gross cracking and soldering continue to be a significant limitation to the die caster's ability to produce a quality product at competitive price levels. The Draw and Forming industry faces more demanding performance from tooling due to the increased use of AHSS (Advanced High Strength Steel),and HSLA (High Strength Low Alloy) steels, especially in the automotive industry.  Thermoset plastic molders are polishing, plating, stripping, polishing, plating in an endless cycle to keep their tooling from sticking and heat checking.

To this end, Badger Metal Tech and its management with NADCA assistance are committed to providing in a timely manner, proprietary quality surface treatments that extends the life and improves the performance of die casting tools as well as enhancing the performance of all other types of perishable tooling, including drawing/ forming/ stamping dies, and thermoset plastic tools.

Based in Wisconsin for the past 23 years, Badger Metal Tech supplies to Die cast die suppliers and end users, the Drawing/Forming/Blanking market, Thermoset plastic mold industry, and other Toolshops, Suppliers,and Labs, as well as Die Casting End Users.

History

The application initial process was developed 1983 to extend the life of cutting tools particularly for taps. During cutting operations, taps experience a severe amount of stress concentration that sometimes causes fatigue at the thread root and then subsequent premature failure of the tool. When the benefits of doing MetaLL ifeÒ to taps was confirmed, the process was tried successfully on other types of cutting tools, including drills, endmills, milling cutters, geometric chasers, etc. One of our cutting tool customers was also a tool shop for die cast tooling. He said his die casting customer was having a problem with premature fatigue cracking on a die and asked if our process could keep this from occurring. The rest is history. The technology has been improved and modified since then.  Today the process is being applied with equal success in the Drawing/Forming/Blanking markets. 

With our TherMaLLifeÒ  process, thermoset plastic molders in 2006 may now have a lower cost and viable alternative to the expense of repeatedly polishing, coating, stripping, polishing, coating, stripping, etc...Dies that mold abrasive glass and fiber additives  or  chlorinate based PVC materials will no longer be attacked by corrosion and heat checking that shortens the  life of H-13 plastic molds.  TherMaLL ifeÒ will not affect the smooth finish required in most plastic tools.  Testing is underway in 2008 to confirm these facts both in the lab and field trials.

Another market that is being explored in 2008 is hot forging.  By utilizing  and combining MetaLL ifeÒ, TherMaLL ifeÒ, and Tungsten Carbide deposition to the surface of hot forging tool (also made from H-13) Badger may be able to significantly extend this industries tool life as well.

"Prior to MetaLL ifeÒ, a die caster's only alternative to repairing heat checking, cavitation breakout, and minor cracking was to weld the tool, resink the tool, or build a new die...all of which are costly and progressively more extreme procedures. For over 25  years Badger Metal's technology has been showing die casters a far less costly and more effective alternative by helping die casters to be proactive regarding their die maintenance procedures. Our roots are planted in the die casting industry with large branches that include customers in the drawing/forming/blanking industry. We continue to mature with NADCA and the rest of the die casting industry by sharing the fruits of our labor and experience."

In June 2001, we began offering a second process that prevents soldering during the die casting operation.  TherMaLLifeÒ  has shown die casters that there is an effective way to stop inter-metallic soldering (adhesion of aluminum to die steel). Since then applications have been found in both the die casting and drawing/forming/blanking/extruding industry and thermoset plastic mold markets..

• Quotations are provided via fax, phone, or email from customers request within 24-48hrs upon receipt of customer castings.  As of January 2002, we  can also download your dxf formatted files from you via ftp (file transfer protocol).

• As of October 15th, 2002, Fast Quotes  (Die Casting or Draw Forming/ Blanking) are now available online for NEW tooling where castings are not available. By a simple click you can email us prints and drawings of the inserts and tooling.

• Our standard lead time is only 3-5 days after receipt of material for MetaLLifeÒ . We also offer, at a premium, an Accelerated Delivery option that in most cases allows us to process a tool with 24-48 hours from receipt. Our TherMaLLifeÒ lead time is only 1 to 2 days.  We utilize a variety of truck freight lines to provide expedited deliveries in both the US and Canada, usually 2-3 days for the extreme east or west coast.  When heat stress tempering is recommended, we can also provide this in a timely fashion.

• Our connection with other types of freight shipping methods include UPS, DHL, Federal Express, and Pilot. Badger's traffic department is familiar with customs requirements for Canadian shipments which enables us to shorten the delay that is usually experienced when trying to move material across the border.

• Corporate membership in NADCA, the Die Materials Committee (DMC), and The Precision Metal Association (PMA) fortify and enables us to be an up-to-date source for consulting to learn what is new in tool steels, heat treat, welding, and coatings. We provide URL links to the universities and organizations that are doing this testing for NADCA.

• New information regarding die casting materials and processes is published in our bulletins which can also be found at this site.  There is also an index to computer tips offered by the President and Founder - Jerry Skoff.  These tips are for addressing common everyday anoyances.

• Are you a movie buff?  Jerry is.  Check out his male and female ratings on current theater viewed movies.

• Other Services

• MetaLL ifeÒ and TherMaLLifeÒ technology never stands still. We do continuing research to find better methods of both applying the process and well as new ways to provide more texturing capabilities, compressive stress characteristics, and soldering resistance benefits. These improvements are then proven and validated by both accredited labs and many field tests.   For those customers that request it, we even track die history of processed part numbers and post it on a secure website.
  Click here to see a: SAMPLE WEB

• Rapid Turn Around in only 3-5 Work Days
• Accelerated Delivery 24-48Hrs for Small Window Situations
• Transit truck shipping to east or west coast in 2-3 days
• Digital Hardness Checks in Casting Area
• Weld Hardness Checks for metal integrity verification
• Surface Texturing for improved metal flow and paint adhesion
• Crack Closure along with Compressive Stress to resist fatigue
• Added Lubricity Phasing to reduce soldering and sticking
• Depth Certification by dynamic control measuring
• Controlled Repeatability as a function of metal hardness
• Die Photomology digitally enhanced
• Historical Database Tracking with secure web site access
• Supported Lab Test Results by universities and testing institutes
• Inter-FAX-Quoting  and email capability
• 800 Service Support in US and Canada
• DMC Participation and NADCA Corporate and Chapter Support
• CD Power Point presentations for End Users
• VHS Videos from Business Today TV Show
• World Wide Web Site - updated daily
• ISO and QS compliancy