Compression -  The depth and value of the compressive stress layer induced during the MetaLL ifeÒ process helps to retard heat checking as well as stopping the propagation of existing cracks.  This is a known fact of physics.  New data from Case Western confirms that lube retention aids not only in die release, but also extends tool life.  Read more below.

Cavitation Effect - MetaLL*ifeÒ takes the smooth surface finish at critical locations of a die's surface and compressively enhances the topography with smooth peaks and valleys.   As the molten metal liquid passes over the gate and runner surfaces, these peaks and valleys disrupt and break up the bubbles quickly, thereby eliminating or drastically reducing cavitation from occurring at more important areas in the die. 

Cooling - New in 2006.  Case Western University has studied the effect of retaining lubricant on the surface of a die.  The residual die lubricant film insulates the surface of the die from direct contact with the molten metal thus lowering the maximum surface temperature.  Experienced temperature drop due to die lube residue on a flat surface reached 400 degrees F after 15,000 cycles.  This reduces thermal stresses at the surface of the die which promotes longer die life. 

The thickness of the residual die lube layer on a flat surface is not uniform and dependent on orientation and spraying variables.  Compressive topography assures better uniform lubricant retention and added fatigue strength.

These findings were confirmed by their standardized dip tank test.  The complete report is available on the Badger Metal DMC-CD - 200602dmc2.

Lab testing using Case Western Reserve University's Dip Tank Test validates a 380% improvement in tool life fatigue relative to thermal crack length and area. Field tests show that when tooling is processed while still new and repeated at predetermined intervals of 20,000 to 50,000 shots that tool life can be significantly extended. With proper die SPC and maintenance, increases of 50% and higher are possible. Processing of used tooling can restore service to tooling that had been considered unusable or scrap. It is not uncommon to obtain an additional 30,000 to 50,000 shots on such tooling plus it can be re-applied if desired.