array_files=new Array(); array_files[0]=new Array(0,1,"http://www.badgermetal.com/feedback/feedback.htm","2009-07-17","34K","Badger Metal Tech feedback form for customer satisfaction ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life,porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure,edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue,dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite ","A form that the Badger Metal Tech customer fills in to indicate satisfaction with Metallife and or Thermallife performance "," Badger Metal Tech feedback form for customer satisfaction Badger Metal Tech, Inc. CUSTOMER SATISFACTION SURVEY. caption Dear Valued Customer, Thank you for giving us the opportunity to perform our MetaLL ifeŇ and/or TherMaLLifeŇ process to your tooling. Our goal is to at least meet and often exceed your expectations. Please take a minute to answer these few questions on our performance which will be acted on if necessary. It will help us to continually address our customers needs to do an even better job for you in the future. Your customer # is all we need to identify your company and tooling that we serviced. Sincerely, Jerald V. Skoff, President Back to Guest Book *Required Information to identify you if you do not enter your customer #. # Please also give us your email address and order # so we can respond. *COMPANY NAME: #CUSTOMER NUMBER (This is the number found above your name on our order, quote, invoice or packing list) *CONTACT NAME: Mr. Mrs. Ms. First Last *ADDRESS: *CITY: *STATE or COUNTRY: State AL AK AZ AR CA CO CT DE DC FL GA HI ID IL IN IA KS KY LA ME MD MA MI MN MS MO MT NE NV NH NJ MN NY NC ND OH OK OR PA PR RI SC SD TN TX VR UT VT VA WA WV WI WY or country ZIP: *PHONE: FAX: #EMAIL: #REFERENCE ORDER #, or PO# * Rating Scale (1) = Not to Expectations (2) = Meets Expectations (3) = Exceeds Expectations 1 2 3 HOW WOULD YOU RATE OUR DELIVERY? 1 2 3 HOW WOULD YOU RATE OUR PACKAGING? 1 2 3 HOW WOULD YOU RATE OUR PAPERWORK? 1 2 3 HOW WOULD YOU RATE OUR PRODUCT QUALITY? 1 2 3 HOW WOULD YOU RATE OUR QUOTING AND OR ACKNOWLEDGMENT PROMPTNESS? 1 2 3 HOW WOULD YOU RATE THE COST OF OUR SERVICE? 1 "); array_files[1]=new Array(0,1,"http://www.badgermetal.com/tl-dc/tltoolingpics.htm","2009-07-17","17K","Stop soldering of die casting dies and increase the life of drawing forming and stamping blanking tooling dies ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ",""," Stop soldering of die casting dies and increase the life of drawing forming and stamping blanking tooling dies Back to previous page Macro Photo of lower right insert 6000 shots brass T-41H + TherMaLL ifeŇ - held to + or - 5 degrees Uniformity of processing assured by TherMaLLifeŇ method Initially processed with T-41 followed by Thermallife Enlargements shown at left and right Sharp edges are retained throughout diffusion process Bed size 28 dia x 48 depth These cores processed with T-41 and Thermallife No size dimensional changes or tolerance concerns Optimized coverage on all sides and surfaces Complete coverage inside recessed areas and ribs TherMaLLifeŇ 440 Stainless Steel tool Complete Coverage by TherMaLLifeŇ Back to previous page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[2]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2002-10-window-of-opportunity.htm","2009-07-17","20K","2002-10-window-of-opportunity to stop heat checking and die failure ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Why die casting dies and die casters have a constant battle on how much to spend on tooling forgetting about the total cost of die maintenance "," 2002-10-window-of-opportunity to stop heat checking and die failure Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. Print this Newsletter NEWS Window of Opportunity Volume#007-10-02 Badger Metal Tech, Inc. October Letter 2002 IN THIS ISSUE CHOICES: FAQ (questions?) 1. Metallife 2. Thermallife 3. Info FNC Quote Request 3. Short Form 4. Standard Form Tool or Die Two recent articles in the Milwaukee Small Business Times drives home the effect China is having on our manufacturing. Click Here to view or download the pdf file. Need a viewer for Acrobat pdf -click here Question: What if every tool shop in the US refused to rework, repair, or make engineering changes to any die not made in the US? In the tooling industry there seems to be a very small window from the time a die is taken out of production to when it will again be required to run product. This is usually the time when all of the repairs, engineering changes, and reworks are performed. A common reason for not being proactive or reactive to a dies condition is there simply isnt any time to get the needed work done. Badger Metal Tech appreciates your needs in this area and has attempted to come up with a possible way to make the window appear a little larger. If we can answer your questions regarding both of our processes and also provide you with a means to communicate your needs prior to shipping a tool to us, this could possibly help to provide the needed time. In this newsletter we will utilize the Badger Metal web sites Frequently Asked Questions (FAQ) section (see sidebar) to answer the most common inquiries we get regarding both of our processes. For those interested, we will direct you to some in depth information regarding our Thermallife process and its roots - see sidebar Info FNC. In addition we will briefly discuss our newly developed online quote "); array_files[3]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2008-03-lamination-correction.htm","2009-07-17","24K","2008-03 Make your lamination of die castings correction permanent ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","One stop shopping for all of your die casting die repair needs "," 2008-03 Make your lamination of die castings correction permanent underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS Make your lamination correction permanent. One stop shopping for die repair and rework. Print this Newsletter Volume#023-03-08 Badger Metal Tech, Inc. March 2008 IN THIS ISSUE mouse over & click button Residual Stress Effects...Part 1 and Part II in one pdf file. Sep 2007 - Part 1 Jan 2008 - Part II Download Here Youve solved your lamination or laminar file problem, remember to make it permanent. In past newsletters we started conversations regarding how well MetaLLifeŇ can correct lamination or blistering problems encountered by many die casters. In a nutshell, the compressive stress effect allows the metal to flow much more efficiently, eliminates trapped gases, and offers metal fatigue protection to counter cavitation effect. Since MetaLLifeŇ is an impaction process, it does not coat or harden the steel. To keep the benefits flowing so to speak, it is necessary that the surface be protected. TherMaLLifeŇ diffuses a protective, hard, wear resistant (1200 vickers) surface to lock in the MetaLLifeŇ flow benefit so it does not dissipate after only a few thousand shots. So the next time you have a lamination problem, remember to use MetaLLifeŇ then make your success permanent by applying the additional protection of TherMaLLifeŇ. Its not only the topography of the surface but whats under it that counts. Back to top They are back. How many die casters remember Lombness Tool in Butler, Wisconsin? Started in 1949, their marketing strategy has dramatically changed, but their mission remains focused on the die casting industry.If you need a die repaired or reworked, this is the tool shop you should call. Thats all they do. They not only have the equipment to handle large tool repairs but also work round the clock "); array_files[4]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2008-06-hd-excellence.htm","2009-07-17","21K","2008-06 Resurrect tooling with Metallife and Thermallife - Excellence Award ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","How Harley Davidson was able to take a retired tool and make it castable again for die casting die repaired "," 2008-06 Resurrect tooling with Metallife and Thermallife - Excellence Award underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS How one company resurrected retired tooling Print this Newsletter Volume#024-06-08 Badger Metal Tech, Inc. June 2008 IN THIS ISSUE mouse over & click button We would like to thank everyone in the industry that voted for us. As a result of your input, Badger received the coveted Supplier Excellence Award at the May 2008 Casting Expo in Atlanta Georgia. We feel honored to have received this award and would like to share it with the rest of the industry. Just Click Here or the left sidebar button. Everyone is going through difficult times now. We receive calls every week concerning companies that are going out of business or from someone that has lost their job as a result. Many of us use our web site as a resource. We are in the process of adding a new section on our links page that addresses this need. Click here or on the sidebar button. On this page is a link that lists individuals that have had this happen to them. Badger Metal hopes to help them continue their die casting career. If you know of any job openings at your company or at other locations, there will be contact information on these individuals along with other information. If you know of anyone that lost their job, tell them to get in touch with us. We all can help. Back to top Some of our customers in the field have been combining the benefits of our MetaLLifeŇ and TherMaLLifeŇ processes for several years now.One question we are frequently asked is How hard is it to weld and polish after these are applied? We recently got our chance to find out. We were asked by a major OEM, in Milwaukee, to process some used tooling. They have been producing recreational vehicles for over 100 years. The test involved a retired die that had high cosm "); array_files[5]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2008-12-tracking-history.htm","2009-07-17","23K","2008-12 Badger Metal Tech offers Metallife and Thermallife tracking of die casting die performance ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","How Badger Metal can track the performance of your die casting die tooling "," 2008-12 Badger Metal Tech offers Metallife and Thermallife tracking of die casting die performance underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS Let Badger track your die maintenance program Print this Newsletter Volume#027-12-08 Badger Metal Tech, Inc. December 2008 IN THIS ISSUE mouse over & click button Matt Werner Surface Engrg. Technician Die History Tracking Keeping track of your die cast tooling maintenance program can be another added responsibility that is very time consuming. Starting in 2009, Badger is offering a free service to historically track your MetaLLifeŇ and TherMaLLifeŇ surface processing requirements for multiple tooling that are on a shot count based schedule. We do this by your input and an Excel spreadsheet. Since your worksheet would be custom made by us, whatever information considered relevant could be included. We are already doing this for some customers that have a family of dies or numerous part numbers receiving MetaLL ifeŇ through the life of the die. This is also being done to track when weight:normalTherMaLLifeŇ is performed. Click on the sidebar button to view a sample spreadsheet that was constructed for one of our customers. From the main page, clicking on any part number reveals another worksheet with complete history and maintenance information. Back to top Feedback Badger is always striving to improve our services. Customer satisfaction is taken very seriously and an integral part to our improvement.Phone calls are appreciated. We know, however, how precious time can be. To take away this burden, there is an easy to use customer satisfaction survey on our web site. Youll see links to it on various pages of our site or just do a search for feedback.We have constructed it so you can quickly complete it and send it by email in a matter of seconds. Once we receive it, depending o "); array_files[6]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2002-06-07-preventing-solder.htm","2009-07-17","15K","2002-06-07-preventing-solder in die casting dies now and in the future ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","The problem of soldering of aluminum in die casting dies "," 2002-06-07-preventing-solder in die casting dies now and in the future Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Print this Newsletter NEWS Solder Prevention - Present & Future Volume#002-06-02 Badger Metal Tech, Inc. June/July 2002 IN THIS ISSUE Recapping 1. Solder Happens 2. Removing It 3. Preventing it Future Technology 1. Qab Press Release 2. How it is done 3. Surface Photo 4. Hardness Graph 5. Composition Graph Since July 2001, Badger has been offering a ferritic nitrocarburizing treatment for tool steels that addresses quite effectively the problem of soldering (aluminum adhering to the composition) of die casting dies. The success of this treatment has been validated by both field and lab testing. Unique to our Thermallife process is that it is not a coating but a highly controlled diffusion treatment that along with adding hardness and improved wear resistance, also develops a compound layer. This compound layer is what provides the barrier between the iron in the tool steel and aluminum in the molten metal from interacting and forming inter-metallic bonds. With each passing day, we are realizing more how common this problem is and its negative effect on the bottom line to the die casting industry. Universities such as Case Western, The Colorado School of Mines, and The Ohio State University are engaged in detailed testing to find the better mouse trap for this problem. NADCA has a special Die Materials Committee (DMC) task force engaged in focused lab projects and field tests to assist in this endeavor. Up until a few years ago, coatings offered the best solution to the soldering phenomena. Unfortunately coatings collapse due to the failure of the substrate. Along with this has been the problem of getting the coating to adhere properly to the treated surface. If there was only a way to overcome these shortcomings. New technology from Australia may be the solution. Back to top Quality Heat T "); array_files[7]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2002-08-choice-reactive-or-proactive.htm","2009-07-17","47K","2002-08-Choosing to be proactive or reactive regarding your die casting die maintenance programs ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Die casters choosing to be proactive and reactive regarding their die casting die maintenance programs "," 2002-08-Choosing to be proactive or reactive regarding your die casting die maintenance programs Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. Print this Newsletter NEWS Choices Volume#005-08-02 Badger Metal Tech, Inc. August Letter 2002 IN THIS ISSUE CHOICES: 1. Metallife FAQ page 2. Thermallife FAQ page 3. Combined Curves 4. Test Coupons 5. Preventing Spalling 6. Die Tracking Sample Page click on chart S tops cracking A pplies well V erifies integrity E nhances fill S ignificantly extends . D ecreases soldering I ncreases lubricity E liminates stresses S lows washout Choices: More than ever in our history, Americans are faced with some very difficult personal choices....Do I stay in the stock market? Where do I invest my money? Can I retire now? Can I afford a new home? Should we have more children? Where will I get the resources to further their education?......... What choices we make can affect not only this generation but future ones as well. Difficult business choices also exist. In the die casting and metal forming markets, increasing bottom line profit is more important than ever if we want to continue to stay in business. Being able to compete globally is rapidly becoming a necessity. More than ever we need to form alliances with our partners to keep business on American soil. With business for the tooling industry being so depressed and the onslaught of foreign competition, especially from China, we have to make the right choices just to survive. As far as tooling goes, you can either be Proactive or Reactive. Proactive choices are designed to head off problems before they occur by anticipating them and taking pre-corrective action. Usually this involves some type of scheduled maintenance program, which is especially difficult to administer with todays scaled back workforces. Companies that have taken "); array_files[8]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2002-11-coating-compatibilities.htm","2009-07-17","16K","2002-11 Metallife and Thermallife Coating compatibilities and proper coating substrate preparation ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","How to prepare for a die casting coating properly by preparing the substrate to support the coating. "," 2002-11 Metallife and Thermallife Coating compatibilities and proper coating substrate preparation Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. Print this Newsletter NEWS Coating Compatibilities Print this Newsletter Volume#008-11-02 Badger Metal Tech, Inc. November Letter 2002 IN THIS ISSUE Compatiblity: Coatings 1. PVDs Tested 3. Adhesion 4. Hardness 5. Thickness Wish List The Holiday Season will soon be upon us. Many plants will be shutdown for extended periods during this time. This provides the perfect time to get your tooling to us for proactive maintenance. We will remain open for this purpose. Question: What special methods for processing should be considered when processing Dievar material? Our December issue will address this question. We estimate there are between 100,000 and 150,000 existing die casting dies in the field that have been processed with either Metallife and/or Thermallife over the past 20 years. Some customers are now asking If I decide to additionally apply a coating to one of these previously treated surfaces, will the coating be compatible? In many instances the current owner or possessor of the die does not know what has previously been done to a tool that is inherited. Since this could cause a huge problem, we decided to do some evaluation to see how well a subsequent coating would adhere to one of our previously treated surfaces. We configured some coupon samples of pre-hardened Viscount 44 hot work die material. These were subsequently processed with four different versions of Metallife. On top of each of these Metallife treated coupons we diffused our Thermallife FNC process making sure that an adequate compound layer was formed during the treatment. HRc indentations were made in three locations to each of the specimens. A total of 12 points were marked on each coupon. Evaluatio "); array_files[9]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2008-09-gross-cracking-causes.htm","2009-07-17","22K","2008-09 Gross Cracking of die casting dies - Hard to Identify ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","More light shed on die casting die gross cracking and what to do about it "," 2008-09 Gross Cracking of die casting dies - Hard to Identify underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS Gross Die Cracking A Hard to Quantify Failure Mode Print this Newsletter Volume#025-09-08 Badger Metal Tech, Inc. September 2008 IN THIS ISSUE mouse over & click button For almost 26 years Badger Metal Tech has been extending the life and improving the performance of tooling for die casting dies, drawing forming stamping tools and other perishable tooling. For Die Casting dies, there is one failure mode that Badger Metal cannot remedy or prevent and is the most expensive mode of failure that can happen. Yet, many times the true cause is hard to determine and nail down since the culprit cannot be definitively identified. We trust by this newsletter that some useful information can be supplied as a reference tool should this problem ever happen to your tooling. By clicking the sidebar buttons, you can find out more about this often misunderstood failure. These side bar buttons link to specific sections on our web site. There you will find useful information on what is believed to be the primary cause of these failures as identified by NADCAs Die Materials Committee. Steel Quality Heat Treat Quality Statistical Process Controls Gross Cracking is one mode of failure that cannot be fixed with MetaLLifeŇ, TherMaLLifeŇ or any other surface engineering technology. It is usually catastrophic in nature and most often requires replacement of the tooling. On the other hand, this failure mode is not related to MetaLLifeŇ, TherMaLLifeŇ or any other surface engineering technology. Its root cause is one of the above. Back to top The first step in solving a problem is recognizing that you have one. In the case of a Gross Cracking failure, it is imperative that the steels metallurgical properties be thoroughly analyzed.The links "); array_files[10]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2009-03-vegas-expo-success-stories.htm","2009-07-17","18K","2009-03 Las Vegas Apr 7-10 2009 Die Casting Success stories ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","More on cavitation bubbles and how they destroy die casting dies unless protected with Metallife "," 2009-03 Las Vegas Apr 7-10 2009 Die Casting Success stories Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS Special Die Maintenance Seminar for Vegas Expo Print this Newsletter Volume#028-03-09 Badger Metal Tech, Inc. March 2009 IN THIS ISSUE mouse over for content & clickbutton Jerry Skoff Surface Engineering. Success Stories T09-074 - Die Maintenance & Repair If you are planning on being in Las Vegas for the Die Casting Congress from April 7th thru the 10th, make sure you sign up for the April 8th Die Maintenance and Repair conference at 2:00 PM in the Versailles Room 1-2 of the Paris Hotel. If you cant make the show or are planning not to go, you can still view our part of the presentation pertaining to success stories from using MetaLLifeŇ in a proactive or reactive manner. We will be presenting 4 of our success stories that deal with different problems and solutions relating to the subject. The keynote speaker will be John Finn from GM. Following this will be Success Stories from various individuals followed by a panel discussion. The latest issue of the DCE (March 2009) gives the complete line up on Page 33. If you cannot go to the meeting, click on the sidebar button. We are anticipating a large turn out for this Congress Session so sign up in advance if possible. Back to top Cavitation Effects Study Our initial presentation to NADCAs die material committee has been shortened and updated to include video and more graphw s. We now have published this in web viewable format.There is also a presentation on the baseline study of how fast tensile stresses build in die casting dies even without pressure and velocity parameters. Click on the sidebar buttons to view both the videos and Power Point presentations which will give you long awaited insight into why your tooling experiences pitting, breakout, and premature fatigue failure.Take a look at our Residual Stress study to confirm how fast stress cracking develops. Back to top back to topics Use your mouse whe "); array_files[11]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2002-05-combining-ml-tl.htm","2009-07-17","36K","2002-05 Combining die casting processes of Metallife and Thermallife to reduce die cast soldering and heat checking ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","How Metallife and Thermallife can be combined to offer die casting dies protection against soldering and thermal fatigue "," 2002-05 Combining die casting processes of Metallife and Thermallife to reduce die cast soldering and heat checking Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked window to exit and return to this newsletter Print this Newsletter NEWS Topic: Combining the two processes Volume#002-05-02 Badger Metal Tech, Inc. May 2002 IN THIS ISSUE 1. Metallife 2. Testimonials 3. Thermallife 4. Lambda Coupons 5. Graphs 6. Combined Graphs 7. Tooling Photos click on graph 72,000 shots click on photo 112,000 shots click on photo China and other global forces are knocking at the US tool makers and die casting industrys doors. It is more important now than ever before in the history of our industry to protect our tooling and manufacturing investment. Since 1983, Badger Metal Tech has been assisting in this task by servicing the die casting industry with its mechanical MetaLL ifeŇ process. It is a well known fact that as a tool loses its hardness and fatigue resistance, heat checking and cracking quickly become a costly cause of die failure. MetaLL ifeŇ has the ability to close minor heat checks under high compression thereby increasing the materials fatigue resistance and retarding softening. This helps to retard further cracking and prevent initial cracking on NEW tooling. Also associated with the process, are some side benefits such as: increased lubricity and lube retention to reduce soldering, improved metal flow, and less porosity concentration. Our MetaLL ifeŇ process has been well validated in both numerous lab tests, and ever continuing field tests. For those that have an interest in reading some of these countless testimonials, click here. With the 2001 introduction of our thermo-chemical diffusion TherMaLLifeŇ process, we can now fully address the other costly phenomena associated with molten aluminum and iron ---- inter-metallic soldering of the aluminum to the tools surface. By combining our two processes it is now feasible for Badger to offer a process that not onl "); array_files[12]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2002-07-dont-take-our-word-for-it.htm","2009-07-17","16K","2002-07-Validation from Case Western University with Metallife testimonies ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Warnings about China taking over our manufacturing "," 2002-07-Validation from Case Western University with Metallife testimonies Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter NEWS Dont Take our Word for It! Print this Newsletter Volume#004-08-02 Badger Metal Tech, Inc. Special July Letter 2002 IN THIS ISSUE 1. Metallife Testimonies 2. Thermallife Testimonies 3. Photos & Samples 4. Metallife Benefits 5. Thermallife Benefits 6. The China Syndrome If you have Acrobat Reader, click on #6 above to see the gravity of this problem we face as a nation. Click Here to Get For almost 20 years, customers from around the world have been using and reporting the benefits of using our Metallife process to increase productivity and extend tool life. This translates to bottom line profits. Many metal formers that did not take a proactive approach to decreasing costs, sad to say, are either no longer in business or have been absorbed by larger corporations. For example, in 1983 there were over 1200 die casters in the US. As of 2002, there are less than 300 that have survived. Part of the problem is not so much the fault of the industry, but rather the lack of support and ever increasing regulatory intervention from our government. Meanwhile China has become extremely aggressive in all manufacturing sectors. Daily we hear shocking stories of tools, components, and full products being copied with little regard to patent and or trademark violations.. Sometimes they quote jobs so far below US pricing that tool shops could make more by buying the tooling from China, then resell it to their customer. What a sad state of affairs. Back to top The same pressures are being applied to other tool shops that supply net shape product tooling for - plastic, drawing, forming, forging and blanking. Our government needs to wake up soon to the fact that China is destroying our manufacturing base in the United States. If no action is taken now, in the future we may not only be dependent on fore "); array_files[13]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2002-09-alliances-to-survive.htm","2009-07-17","21K","2002-09-Building-US-alliances-to-survive in the die casting industry ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Prophecy of the manufacturing future to come and the decline of the die casting industry "," 2002-09-Building-US-alliances-to-survive in the die casting industry Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS Alliances Print this Newsletter Volume#006-09-02 Badger Metal Tech, Inc. September Letter 2002 IN THIS ISSUE CHOICES: Quick Link 1. Contact your Congressmen Tooling Related 2. Badger Metal Links 3. Die Tooling Source 4. Requesting Tooling Quote Solder Removal Equipment 5. Removing Soldering 6. Ultrasonic Cleaning Investors Business Daily 09/13/02 Trade Gap Reaches Record in Q2 The current account deficit hit 130 bil as a recovering economy gobbled up foreign cars and other goods. The previous record was 112.5 bil, set in Q1. The current account measures not just trade in goods and services, but also investment flow. The U.S. ran a 122.6 bil deficit in goods, up from 106.4 bil in Q1. After reading this article, and after seeing the excellent letter in the September issue of Die Casting Engineer magazine from the Chairman of the Board for NADCA, it confirms to us what most already know: Foreign competition will nail the coffin lid on manufacturing in the U.S. unless we begin to take a proactive approach to the products we are selling. We also need to better inform our government officials about the situation and our discontentment. By forming alliances with other US suppliers in our industry, we can offer products and services that are not available in China or other foreign countries. In our previous issue we emphasized the importance of being Proactive instead of Reactive. One way to be more proactive is to form solid alliances with tool shops, die lube suppliers, and other companies that provide products and/or services that are common to our industry. By working together, we can compound our efforts that will benefit us as a country. Back to top Badger is doing this on our links page at our we "); array_files[14]=new Array(0,1,"http://www.badgermetal.com/brochures.htm","2009-07-17","29K","Complete sets of brochures in pdf format ","",""," Complete sets of brochures in pdf format Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com 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 if necessary return to guestbook page Please download any or all of our brochures in pdf format. Hold your mouse over any button to get a short description of the contents. Below each button is some information regarding size, pages, and content. You may either right-click and choose Save As for the file or double click to download and open the file. Die Casting Preview before you buy Available for Purchase from NADCA #501 Rapid build up of residual tensile stress for a polished only steel specimen Draft of NADCAs publication 531. Available for purchase NADCA #531 Reports from NADCAs Die Materials Committee for various projects conducted This brochure has 8 pages of complete information on our MetaLL ifeŇ process along with specific case histories A 4 page Case Western Reserve University study report that evaluated the compressive stress benefits as it relates to stopping thermal cracking A 5 page Case Western Reserve University study report on the detrimental effects of EDM and its relationship to fatigue of H-13 tool steel. In June 1995, Case did 4 page article in Die Casting Engineer magazine that endorsed the benefits of compressive stress and the MetaLL ifeŇ process. Drawing /Forming Blanking/Stamping Power Point Slide Presentations 14 meg 4.3 meg 1.8 meg .5 meg .4 meg This 6 page brochure discusses all aspects of drawing, forming, and blanking and their relationship to failure modes and preventative action This short brochure gives pricing information Perishable Cutting Tools A 4 page brochure thatdefines our process as applied to perishable cutting tools of all types along with a multitude of case studies for different types. Page was last modified Sunday, July 12, 2009 home about u "); array_files[15]=new Array(0,1,"http://www.badgermetal.com/coatings/coating-thickness-hardness.htm","2009-07-17","26K","Values of hardness and thickness of coatings applied over Metallife ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life,porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure,edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue,dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite ","Thickness of various coating applied over Metallife along with the relative hardness of the coatings "," Values of hardness and thickness of coatings applied over Metallife Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com HRC readings of coatings applied over MetaLL ifeŇ - TherMaLL ifeŇ combinations (FUTURA NANO is Balzers proprietary TiAlN) return to coupons back to benefits Thickness measurements of coatings applied over MetaLL ifeŇ - TherMaLLifeŇ combinations (taken with X-ray diffraction) (FUTURA NANO is Balzers proprietary TiAlN) return to coupons Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[16]=new Array(0,1,"http://www.badgermetal.com/coatings/coating-indent-microphotos.htm","2009-07-17","27K","Excellent adhesion properties for coatings of all types ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life,porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure,edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue,dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite ","Various coating applied over Metallife which is used to prepare the substrate to prevent coating failure in die casting dies H-13 "," Excellent adhesion properties for coatings of all types Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com These micro photos show the adhesion properties of each coating to a previously treated coupon sample. back to benefits TiAlN - Adhesion excellent - one small anomaly at T-41 indent location. (This is the current preferred coating by field die casters because of its high oxidation temperature and expansion characteristics) return to coupons CrN - Adhesion excellent - minor anomalies outside indent location. (This is another preferred coating by field die casters that also exhibits good flexibility and adequate oxidation temperatures for use in die casting) return to coupons TiN - Adhesion Good - No anomalies (used by some die casters, however, low oxidation temperature and limited expansion capability do not permit this coating to be used on die casting die inserts or high temperature applications. Resulting coating failures have galvanic reaction characteristics) return to coupons CrC - Poor adhesion and non-uniformity of thickness (At one time was considered an equal to CrN. Thickness of coating varied from 1.4 to 8.8 microns and exhibited) return to coupons back to benefits Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[17]=new Array(0,1,"http://www.badgermetal.com/coatings/coating-adhesion-test.htm","2009-07-17","39K","Substrate preparation for coating using Metallife ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life,porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure,edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue,dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite ","testing conducted to show how well Metallife can be applied in combination with coatings "," Substrate preparation for coating using Metallife Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Adhesion Testing of PVD Coatings after Substrate - MetaLL ifeŇ followed by TherMaLLifeŇ then coated See Also Compressive Stress Evaluation - TiAlN applied over MetaLL ifeŇ - 4 slide PowerPoint back to benefits Purpose of Test: Badger Metal in conjunction with Balzers wanted to ascertain the viability of applying a coating to a TherMaLLifeŇ treated surface. Many tools in existence today have been previously MetaLL ifeŇ and/or TherMaLLifeŇ processed (ferritic nitro carburized). Both of these processes provide superior die failure and soldering protection even without subsequent application of a coating. The importance of a coatings substrate preparation is now being investigated by NADCAs Die Materials Committee Coating Taskforce. Since coatings are thin, by nature, it is important to have a properly prepared substrate to support the coating. Some customers have asked if it is possible to directly apply a PVD coating over our processes if so desired. PVD (physical vapor deposition) coatings are applied at a lower temperature than CVD (chemical vapor deposition) coatings. With one exception, our tests confirmed adhesion is good to excellent in all cases. Substrate Preparation: Four rectangular pieces of Viscount 44 (prehardened H-13) were first processed with MetaLL ifeŇ using four different processes (T-10, T-21, T-41, T-61). The lower the number the smoother the resulting surface finish. Subsequent to this our TherMaLLifeŇ (ferritic nitro carburizing) process was applied using our standard H-13 recipe. The T-10 finish is an extremely smooth surface but r "); array_files[18]=new Array(0,1,"http://www.badgermetal.com/coat-hard.htm","2009-07-17","22K","Coating comparison Charts ","",""," Coating comparison Charts Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Comparison of various surface coatings and their hardness ratings in Vickers TD = High Temperature Proprietary (requires re-heat treatment) CVD = Chemical Vapor Deposition = High Temperature PVD = Physical Vapor Deposition = Low Temperature FNC = Ferritic Nitrocarburizing TherMaLLifeŇ = Automated Ferritic Nitrocarburizing Click on this graph to view a larger image Extremely hard surfaces can be just as detrimental as a softer surface hardness Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[19]=new Array(0,1,"http://www.badgermetal.com/quoteshort-dc.htm","2009-07-17","56K","Quote Request Form Short - Die Casting ","",""," Quote Request Form Short - Die Casting Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files return to home page for die casting DIE CASTING RFQ Submit this form if a casting is available SHORT FORM for pricing if casting being sent Badger Metal Tech - Request for Quote MetaLL ifeŇ and/or TherMaLLifeŇ Use the tab key to jump from field to field MetaLL ifeŇ is priced based on surface area TherMaLLifeŇ is priced based on total weight of the lot Items marked with a red (*) are required fields Customer Information - Quote or RFQ # Metallife None - Thermallife None Date Quote Needed When should we follow-up? How many days can tooling be out of production? 1 work week 1 2 3 4 5 2 work weeks 3 work weeks or more * Will you need Accelerated Delivery? No Yes * (normal delivery is ARO 1-2 days for TherMaLLifeŇ and 3-5 days for MetaLL ifeŇ) Approximate Ship Date to Badger if approved Company Name: * Person Requesting Quote: * Part # * if not known enter ? Part Name * if not known enter ? Description * if not known enter ? Dimension and Weight Information Tooling dimensions are in inch mm Please specify here. Tooling weights are in lbs kilos use this handy conversion link if needed For - TherMaLLifeŇ (include steel type identification form) Approx Weight (lbs) of All Insert, Slides, Cores, Etc. Total number of pieces Steel Type H-13 Premium H-13 DieVar 2867 Thyssen KDA1 Maraging other (information is critical, especially if DieVarŇ) (if only TherMaLLifeŇ is requested, jump to bottom of this form Continue here for MetaLL ifeŇ Number of Covers 1 2 3 4 5 6 7 8 other * if other Double Impression No Yes Insert Max Length * Max Width * Max Height * Number of Ejectors 1 2 3 4 5 6 7 8 other * if other Double Impression No Yes Insert Max Length * Max Width * Max Height * Will Slides be processed? No Yes * "); array_files[20]=new Array(0,1,"http://www.badgermetal.com/stuff/erunt/faq-erunt.htm","2009-07-17","25K","ERUNT and NTREGOPT FAQ ","",""," ERUNT and NTREGOPT FAQ Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com ERUNT and NTREGOPT Frequently Asked Questions (FAQ) This page answers some of the most commonly asked questions regarding ERUNT and NTREGOPT. Please look here first if your question is already answered. Question: Do ERUNT and NTREGOPT run on 64-bit Windows? Answer: Yes, version 1.1j and later fully support all 64-bit editions of Windows. Older versions may cause problems, so be sure to use the latest one on these systems. Question: Do ERUNT and NTREGOPT run on Windows Vista? Answer: Yes. To make sure the programs are executed with proper administrative privileges, you should however turn off User Account Control in Vista’s system settings. Question: Do I need to uninstall old versions of ERUNT or NTREGOPT before installing a new one? Answer: No, simply install the new version over the old one. This will also keep any settings you may have specified in the ERUNT.INI file. (During installation, the current ERUNT AutoBackup shortcut is deleted from the start menu’s Startup folder if present. If you had customized AutoBackup’s command line then you will need to do so again after installation of the new version.) Question: Should I disable Windows XP’s System Restore function when using ERUNT? Answer: Yes! Though System Restore backs up more than just the registry, the registry is essentially all you need to revert your system to a previous state. Advantages of ERUNT over System Restore are that each restore folder is standalone and independent of the others, minimizing the risk of restore failures, and that a restore can easily be done from outside Windows. Also, ERUNT backups usuall "); array_files[21]=new Array(0,1,"http://www.badgermetal.com/badger-metal-casting-photos.htm","2009-07-17","21K","Die for Badger Metal Casting 2000 ","",""," Die for Badger Metal Casting 2000 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Badger Metal Casting - 2000 Casting Side from H-13 cover side of die Casting Side from P20 side of die note premature heat check cracking return to previous page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[22]=new Array(0,1,"http://www.badgermetal.com/bmtg","2009-07-17","13K","Badger Metal guarantees extended life for die casting dies ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life,porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure,edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue,dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite ","a description of our guarantee which no other coating or surface treating company offers. "," Badger Metal guarantees extended life for die casting dies Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files We Guarantee will increase tool life +25% or get your cost for processing back! 1. Die must be processed when new (preferred prior to sampling*) (*changes made after first sampling will be reprocessed no charge or for minimal cost). 2. Die must have at least both sides (cover, ejector) processed. 3. Die must be re-processed at least at its normal (= 40-60%) half life or sooner. 4. Die must have expected shot life stated initially prior to processing when new. 5. Die must not have pre-mature failure ( failure prior to half life processing ). 6. If engineering changes are made after MetaLL ifeŇ processing, guarantee is void unless die is reprocessed. Guarantee is limited to amount invoiced for processing. Badger is not responsible for any consequential and/or incidental costs or expenses incurred by customer. Guarantee is non-transferrable from original invoiced agent or die casting company. Last modified - Friday July 17, 2009 "); array_files[23]=new Array(0,1,"http://www.badgermetal.com/stuff/JPG-Resize/photo-resizer.htm","2009-07-17","26K","Resize Photos for Emailing by Drag and Drop ","",""," Resize Photos for Emailing by Drag and Drop Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Picture Resizer 2.0 December 2007 An easy-to-use and free tool for batch resizing of JPG pictures and photos. How to use it? Download and unzip PhotoResize400.zip and place the file on your desktop. Drag and drop JPG files or folders with JPG files on the application icon. The tool will resize JPG images and save them next to the originals. Names of the new pictures will be based on the original names, with a suffix indicating their size. For example, the resized version of MyPhoto.jpg will be called MyPhoto-400.jpg, where the number 400 indicates the size of the picture. Configuration By default, the application resizes the pictures to 400 pixels and preserves original aspect ratio. The size of output pictures is controlled by the name of the application. To generate 200 pixels images, simply rename the application to PhotoResize200.exe Tip: it is possible to have multiple copies of the application with different names to generate different image versions quickly. If you want to manually control both width and height of the output image, rename the application to PhotoResizeWxH.exe, where W is the requested width and H the requested height. It is your responsibility to set correct aspect ratio in this case. Highlights The tool is using high-quality resizing method, where color of each pixel is a weighted average of all covered pixels from the original image. Linear interpolation is used when zooming in. The algorithm is optimized to work with gamma-corrected pictures. High speed. Whats new in version 2.0 Custom destination folder and file name - the -c switc "); array_files[24]=new Array(0,1,"http://www.badgermetal.com/stuff/JKDefrag/jk-defrag.htm","2009-07-17","22K","Free Defrag Program - zipped ","",""," Free Defrag Program - zipped Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Screenshot of JK Defrag Program download For Windows 2000/XP/Vista JkDefrag is a disk defragmenter and optimizer for Windows 2000/2003/XP/Vista/X64. Completely automatic and very easy to use, fast, low overhead, with several optimization strategies, and can handle floppies, USB disks, memory sticks, and anything else that looks like a disk to Windows. Included are a Windows version, a commandline version (for scheduling by the task scheduler or for use from administrator scripts), a screensaver version, a DLL library (for use from programming languages), versions for Windows X64, and the complete sources. Website http://www.kessels.com/JkDefrag/ There is no setup or install and no configuration file. All you have to do is download the zip and unpack anywhere you like. The programs are ready to run, even from memory stick or cdrom. The zip contains the following 3 programs: JkDefrag.exe Windows version. This is what most people will use. No installation or configuration necessary, its ready to run and will automatically process all the mounted, writable, fixed volumes on your computer JkDefragCmd.exe Commandline version. Specially designed to be run automatically in the background, or from administrator scripts. See the Commandline chapter below for a list of commandline options, and the Frequently Asked Questions on how to run it automatically with the Windows Scheduler. JkDefragScreenSaver.scr + JkDefragScreenSaver.exe Screen saver version. Move (or copy) these two files to the windows folder on your harddisk (usually c:Windows or c:Winnt). It will automatically become vis "); array_files[25]=new Array(0,1,"http://www.badgermetal.com/area-formulas.htm","2009-07-17","19K","Area Formulas for various 3D shapes ","",""," Area Formulas for various 3D shapes Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Common Geometric Formulas Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[26]=new Array(0,1,"http://www.badgermetal.com/2002-lambda-coupons.htm","2009-07-17","21K","Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Below are photos of the actual coupons that were used for plotting compression curves. Why we use Lambda? Graph Page A separate electronic newsletter summarizing these tests will be published in the 1st quarter of 2002 (Choices). topography with solder protection return to coupon page no topography change with heat check protection return to coupon page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[27]=new Array(0,1,"http://www.badgermetal.com/tl-dc/dievar-tl.htm","2009-07-17","24K","Stop soldering of die casting dies and increase the life of drawing forming and stamping blanking tooling dies ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ",""," Stop soldering of die casting dies and increase the life of drawing forming and stamping blanking tooling dies Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Micrograph structure of diffusion and compound (white layer) DievarŇ Steel by Uddeholm - cross section at 200x Improper application - large irregular zones. Proper initial application with Uddeholm zone and layer. Second application to previously processed areas and welded areas as well. Third application to again both welded and previously processed areas as well. back to TherMaLLifeŇ main page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[28]=new Array(0,1,"http://www.badgermetal.com/tl-dc/thermallife-dc.htm","2009-07-17","86K","Stop soldering of die casting dies and increase the life of drawing forming and stamping blanking tooling dies ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ",""," Stop soldering of die casting dies and increase the life of drawing forming and stamping blanking tooling dies Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Die Casting Electronic Newsletters coating after MetaLL ifeŇ or TherMaLLifeŇ? Tooling Benefits click on above photo for advanced information click on award for more info Supplier Excellence May 2008 MetaLLifeŇ TherMaLLifeŇ TherMaLLifeŇ An exclusive Badger Metal Tech surface treatment that offers the benefits of ferritic nitrocarburizing performed in a fully automated system.The only one of its kind in the United States. TherMaLLifeŇ is a ferritic nitrocarburizing treatment. Since it is done at a comparatively low temperature and is a diffusion process, distortion, size, and tolerance changes of the tool are not a problem. This process has application benefits not only for die casting dies but also for other forms of perishable tooling including: H-13 Die Casting Dies H-13 Thermoset Plastic Molds Permanent Molds Drawing Dies Stamping Dies Blanking Dies Forming Dies Forging Dies With the addition of the TherMaLL ifeŇ we have expanded our capabilities to other areas of tooling and can now offer benefits such as: Increased wear resistance Anti-galling properties Improved fatigue strength High surface hardness Corrosion resistance (except in the case of stainless steels) Resistance to the softening effect of heat Since 1983, MetaLL ifeŇ has become the standard in the Die Casting Industry for compressive protection against heat checking for NEW die cast tooling and its ability to close and retard additional thermal cracking on USED tooling. The MetaLL ifeŇ topography created in the case of H-13 or o "); array_files[29]=new Array(0,1,"http://www.badgermetal.com/tl-dc/diptank-thermallife.htm","2009-07-17","22K","Stop soldering of die casting dies and increase the life of drawing forming and stamping blanking tooling dies ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ",""," Stop soldering of die casting dies and increase the life of drawing forming and stamping blanking tooling dies Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Case Western Dip Tank Test TherMaLLifeŇ Test View the general specifications for this test that was completed and under evaluation by NADCAs Die Material Committee back to menu Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[30]=new Array(0,1,"http://www.badgermetal.com/tl-dc/dievar-dc.htm","2009-07-17","37K","Stop soldering of die casting dies and increase the life of drawing forming and stamping blanking tooling dies ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ",""," Stop soldering of die casting dies and increase the life of drawing forming and stamping blanking tooling dies Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Uddeholms DievarŇ Steel special considerations steel type identification form As noted in the May 2003 issue of Die Casting Engineer magazine, some steels, such as these, have high percentages of chromium, nickel, titanium and other alloys and tend to nitride more quickly but take longer developing the compound layer. DievarŇ has about the same percentage of Chromium as does H-13 (Cr 5%), however, because of the chromium matrix, the nitriding time is accelerated for a given temperature and time. Uddeholm does not recommend a compound layer with a depth of more than 0.0002 - 0.0003 inches for most die casting applications which works out well with a shorter time for diffusion. One can see the importance of knowing the steel type and why we require completion of the to accompany any tooling for TherMaLLifeŇ. Detailed Cross Section Micro photos Shortened Time Longer time - (for H-13) Tests at Case Western and The Colorado School of Mines show that cracking just below the diffusion zone develops if the zone or compound layer is too deep. Ideally a thin compound layer is best for solder protection along with a diffusion zone for thermal protection. NEW or USED TOOLING - First Application Uddeholm DievarŇ evaluation has shown that: a) At 1075°F - for approximately 1 hour a diffusion depth of 0.002 - 0.003 inches is obtained. b) Because of this temperatures proximity to final temper, an adjusted lower temperature is used in the TherMaLLifeŇ recipe with extended time to obtain the same results. After "); array_files[31]=new Array(0,1,"http://www.badgermetal.com/tl-dc/faqtl-dc.htm","2009-07-17","80K","Stop soldering of die casting dies and increase the life of drawing forming and stamping blanking tooling dies ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ",""," Stop soldering of die casting dies and increase the life of drawing forming and stamping blanking tooling dies Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Die Casting Frequently Asked Questions Compressive Stress benefits of applying MetaLL ifeŇ after TherMaLLifeŇ to NEW tooling validated by Lambda labs. click on photo return Here are some facts regarding TherMaLL ifeŇ that should answer common questions regarding our diffusion treatment. Those that have used our NEW diffusion process are seeing measurable cost saving improvements in tooling performance. What makes TherMaLLifeŇ unique is that it is performed in an automated, controlled atmosphere. This allows us to automatically control temperatures, gas velocity, and pressures to assure maximum repeatability. TherMaLLifeŇ, available since July 2001, is only available from Badger Metal Tech, Inc. in Menomonee Falls, Wisconsin. Our certificate of compliance assures your satisfaction. Make sure you request this when placing your order especially if you have ISO or QS requirements. Application Frequency Criteria for correct TL process Hot Work Steel Concerns? Applying over PVD coatings Dievar, 2367 and special steels Perform on USED tooling Applying PVD coatings over Differences in TL processes Size change or distortion Assurance of Performance H-13 v/s Anviloy Welding Cleaning Methods Flaking, chipping, peeling What about lubricity? Stress Temper - Effect - None Topic Response How sensitive is the compound surface layer to cleaning? It is recommended that the TherMaLL ifeŇ surface be cleaned so as not to disturb the compound layer. No more than a 20psi glass bead, or Scotch-BriteŇ should be used. "); array_files[32]=new Array(0,1,"http://www.badgermetal.com/tl-dc/dce-may2003-tl-article.htm","2009-07-17","28K","Stop soldering of die casting dies and increase the life of drawing forming and stamping blanking tooling dies ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ",""," Stop soldering of die casting dies and increase the life of drawing forming and stamping blanking tooling dies Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com NADCA ARTICLE May 2003 - Page 52 Major Advances in Ferritic Nitrocarburizing Open, Download, Print - Complete Article with all photos The following are specific topics discussed in this article. To quickly jump to a specific section, click on the underlined link. To the right is a short definition of the material discussed.. Simply click on the hyperlink underlined text which will open in a new window containing more detailed information. This article is reproduced and available on the Badger Metal Tech literature CD that is mailed in two forms…Standard and a smaller Business card size CD. By using this type of media, we are able to keep our technology information current. You may also print out the entire article in PDF format. Adhesion Testing Balzers coatings can be successfully applied over the process Historic Timeline The history of nitriding from the early 1900s through the present. Types FNC Defining the various types of nitriding that are available. Criteria Atmosphere parameters. Heat Transfer Factors affecting ideal heat transfer during nitriding. Critical Parameters Critical factors to consider to obtain maximum benefit. Ammonia Dissociation Advances in measuring diffusion depth and process monitoring. Automated Equipment Photos of equipment being used at Badger Metal Tech Table TherMaLLifeŇ Superiority comparison to other FNC and nitriding processes. Solder Test Case Validation Tutorial at Case Western Reserve University in 2002. Solder Summary Summary of conclusions from Case Wes "); array_files[33]=new Array(0,1,"http://www.badgermetal.com/cert-compliance.htm","2009-07-17","37K","Certificate of Compliance Defined ","",""," Certificate of Compliance Defined Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Here is a sample of our Certificate of Compliance that assures your satisfaction - more! MetaLL ifeŇ and TherMaLLifeŇ are available only from Badger Metal Tech in Milwaukee, Wisconsin Every tool receives a documented Receiving Inspection to check for incoming shipping damage and to check/confirm existing Cold Work Rockwell or Hot Work Rockwell hardness measurements before and after heat stress tempering, if applicable. The tooling then is thoroughly cleaned to prepare for processing and prevent contamination while in the controlled atmosphere equipment. MetaLL ifeŇ is performed at room ambient conditions in a controlled environment and can be duplicated to assure repeatable compliancy and no change of tolerances. The T process designates specific application pressures, velocity, dwell, media size, classification, and process steps that have been researched and developed exclusively for perishable tooling and hot and cold work tool steels. All specifications and call outs used are documented for future reference to provide the repeatability, consistency, and topography* effects to the surface that only MetaLL ifeŇ can provide. (*topography is a by-product proportional to the hardness of the surface of the tool. It should not be confused with the resultant effective compressive stress effect) TherMaLLifeŇ is performed in controlled atmosphere equipment at temperatures that are below critical. Again there are no changes in tolerance or size. The recipe for temperature, time, gas velocity, and composition is determined by the type of tool steel being treated. The process i "); array_files[34]=new Array(0,1,"http://www.badgermetal.com/field-ml.htm","2009-07-17","121K","Testimonials and Letters for Metallife ","",""," Testimonials and Letters for Metallife Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com : Testimonials Letters - Over 100,000 dies processed since 1983. (Our testimonial letters are coded to protect our clients security) Specific 20 year endorsement of Metallife on aluminum, zinc, and brass dies Dramatic Improvement in Tool Life (#670 3/07/09) Less sticking soldering and drag of die casting Improved magnesium flow Reduced buffing and polishing time of casting Reduced die casting pressure - testimonial letter Field Result Comments - Preceding # is internal ref number for customer. (Our customer comments are coded to protect our clients security) Improved performance and extended life Die casting dies for brass Die casting Bronwite brass (NEW #670 03/2009) Crack closure and prevention Soldering problems resolved or reduced Reduction in gate erosion Better Paint Adhesion Reduction in porosity problems Drawing field tests Blanking and cutting tools Testimonial Letters and Emails Preceding # is an internal reference case number for the customer. 20 year endorsement of MetaLL ifeŇ #882 - WI - I have been a satisfied customer of Badger Metal Tech for nearly 20 years. MetaLL ifeŇ consistently delivers on its promise to substantially improve tool life in zinc, aluminum and magnesium die cast dies. In brass die cast tooling, regular use of MetaLL ifeŇ coupled with proper tool steel selection/application and heat treat process increased tool life EXPONENTIALLY! Jerry and his Badger Metal Tech, Inc. staff are extremely helpful and always available for any type of support needed. MetaLL ifeŇ works because its principle is founded on solid physics and metallugical "); array_files[35]=new Array(0,1,"http://www.badgermetal.com/quoterequest-dc.htm","2009-07-17","66K","Quote RFQ Die Cast ","",""," Quote RFQ Die Cast Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files return to home page for die casting DIE CASTING RFQ Submit this form if a casting is not available Click here to use the short form if a casting is being sent Badger Metal Tech - Request for Quote MetaLL ifeŇ and/or TherMaLL ifeŇ Use this form to email us your tooling requirements along with any necessary drawings and photos if you are not sending us a casting. Use the tab key to jump from field to field MetaLL ifeŇ is priced based on surface area TherMaLLifeŇ is priced based on total weight of the lot Items marked with a red (*) are required fields Customer Information - Quote or RFQ # Metallife None - Thermallife None Date Quote Needed When should we follow-up? How many days can tooling be out of production? 1 work week 1 2 3 4 5 2 work weeks 3 work weeks or more * Will you need Accelerated Delivery? No Yes * (normal delivery is 1-2 days for TherMaLLifeŇ and 3-5 days for MetaLL ifeŇ) Approximate Ship Date to Badger if approved Company Name: * Person Requesting Quote: * Client Customer: * if not known enter ? Part # * if not known enter ? Part Name * if not known enter ? Description * if not known enter ? Dimension and Weight Information Tooling dimensions are in inch mm Please specify here. Tooling weights are in lbs kilos use this handy conversion link if needed For - TherMaLLifeŇ (include steel type identification form) Approx Weight (lbs) of All Insert, Slides, Cores, Etc. Total number of pieces Steel Type H-13 Premium H-13 DieVar 2367 SB KDA1 Maraging other (information is critical, especially if DieVarŇ) (if only TherMaLLifeŇ is requested, jump to bottom of this form Continue here for MetaLL ifeŇ Number of Covers 1 2 3 4 5 6 7 8 other none * if other Double Impression No Yes Insert Max Length * Max Width * "); array_files[36]=new Array(0,1,"http://www.badgermetal.com/dc-dfs-ml.htm","2009-07-17","26K","Choose Metallife for Die Casting or Drawing, Forming, Blanking ","",""," Choose Metallife for Die Casting or Drawing, Forming, Blanking Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Die Casting Drawing Forming Blanking + Die Casting Metal Forming Copyright © 2003-2006 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[37]=new Array(0,1,"http://www.badgermetal.com/contact.htm","2009-07-17","21K","Metallife and Badger Metal Tech full contact information ","heat checking, fatigue cracking,breakout from cavitation, Metallife, Thermallife, Metalife, Thermalife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue,dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, reduce die casting scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, Metal life, Metal life process, metallife process, die casting surface treatments, die surface treatment, die surface engineering, metal life surface treatment, die lube, die lubricant, die casting lubricant, die lubricity, lubricity, shot peening, metallife peening, die shot peening, peening, laser peening, precision peening, precision peening process, precision shot peening, precision shot peening process, residual stress, controlled residual stress, compressive stress texturing, controlling residual stress, reducing residual stress, residual compressive stress, compressive stress, surface compression, weld peening, weld shot peening, cycle failure, surface coating, die casting coating, coating process, die surface coating, mechanical coating, mechanical coating process, casting porosity, breakout, die breakout, diamond polishing, diamond polish, flash, flash reduction, reduced flashing, flashing, gross cracking, NADCA, North American Die Casting Association, shot blasting, abrasive blasting, blasting, stress relief ","Full contact information including maps addresses and other information on compressive stress and die surface treatments "," Metallife and Badger Metal Tech full contact information Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[38]=new Array(0,1,"http://www.badgermetal.com/quoteshort-dfs.htm","2009-07-17","50K","Quote Request Form Short - Drawing/Forming/Blanking ","",""," Quote Request Form Short - Drawing/Forming/Blanking Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files return to thermallife home page for draw forming / blanking DRAWING/FORMING/BLANKING RFQ Submit this form if a drawing is available SHORT FORM for budgetary pricing Badger Metal Tech - Request for Quote MetaLL ifeŇ and/or TherMaLLifeŇ Use the tab key to jump from field to field MetaLL ifeŇ is priced based on surface area TherMaLLifeŇ is priced based on total weight of the lot Items marked with a red (*) are required fields Customer Information - Quote or RFQ # Metallife None - Thermallife None Date Quote Needed When should we follow-up? How many days can tooling be out of production? 1 work week 1 2 3 4 5 2 work weeks 3 work weeks or more * Will you need Accelerated Delivery? No Yes * (normal delivery is ARO 1-2 days for TherMaLLifeŇ and 3-5 days for MetaLL ifeŇ) Approximate Ship Date to Badger if approved Company Name: * Person Requesting Quote: * Part # * if not known enter ? Part Name * if not known enter ? Description * if not known enter ? Dimension and Weight Information Tooling dimensions are in inch mm Please specify here. Tooling weights are in lbs kilos use this handy conversion link if needed For - TherMaLLifeŇ (include steel type identification form) Approx Weight (lbs) of Die Compoents, Etc. Total number of pieces Steel Type D2 A2 M? other CMPV? (this information is mandatory) (if only TherMaLL ifeŇ is requested, jump to bottom of this form Continue here for MetaLL ifeŇ Number of Draw or Blanking Dies ? 1 2 3 4 5 6 7 8 other * if other Insert Max Length * Max Width * Max Height * Number of Draw or Blanking Punches ? 1 2 3 4 5 6 7 8 other * if other Insert Max Length * Max Width * Max Height * Number of Other Components No Yes * if other Slide Max Length * Max Width * "); array_files[39]=new Array(0,1,"http://www.badgermetal.com/flowchartlg.htm","2009-07-17","19K","Flowchart Large View ","",""," Flowchart Large View Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com For a printable version - click here Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[40]=new Array(0,1,"http://www.badgermetal.com/history.htm","2009-07-17","51K","History and Mission Statement ","",""," History and Mission Statement Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Mission Statement Die and Mold Maintenance Specialists Over 25 years of experience in die materials, metallurgy, and manufacturing make Badger Metal Tech the reliable resource for die and mold maintenance. North American Manufacturing relies on Badger Metal Tech to provide comprehensive Preventative Maintenance Programs for die cast dies and plastic injection molds.Maximizing tooling life and enhancing performance are one of the keys to controlling costs and saving energy. Using the latest in application technology, MetaLL ife and TherMaLL ife are two cost effective surface treatments used extensively in the tooling industry. Die Casting Die Thermal Fatigue and surface heat checking, gross cracking and soldering continue to be a significant limitation to the die casters 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 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 Wisc "); array_files[41]=new Array(0,1,"http://www.badgermetal.com/Pricing/dc-pricing/pricemldc01-2006.htm","2009-07-17","20K","Pricing Metallife Die Casting Jan 1 2006 ","",""," Pricing Metallife Die Casting Jan 1 2006 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Printable pdf version of this page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[42]=new Array(0,1,"http://www.badgermetal.com/Pricing/dfs-pricing/pricemldfs01-2006.htm","2009-07-17","20K","Pricing Metallife Drawing Forming Blanking Jan 1 2006 ","",""," Pricing Metallife Drawing Forming Blanking Jan 1 2006 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Printable pdf version of this page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[43]=new Array(0,1,"http://www.badgermetal.com/Pricing/Hob-Pricing/Hob-Pricing.htm","2009-07-17","9K","Metalife Pricing for Hobs ","",""," Metalife Pricing for Hobs Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Printable pdf version Printable pdf version "); array_files[44]=new Array(0,1,"http://www.badgermetal.com/badger-metal-die-photos.htm","2009-07-17","21K","Die for Badger Metal Casting 2000 ","",""," Die for Badger Metal Casting 2000 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Die for Badger Metal Casting - 2000 return to previous page H-13 cover side of die P20 side of die return to previous page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[45]=new Array(0,1,"http://www.badgermetal.com/Pricing/pricetl2006-06.htm","2009-07-17","19K","Pricing Thermallife 06-2006 ","",""," Pricing Thermallife 06-2006 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Printable pdf version Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[46]=new Array(0,1,"http://www.badgermetal.com/dmc-reports.htm","2009-07-17","38K","NADCA Die Materials Task Force Report Section ","",""," NADCA Die Materials Task Force Report Section Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Die Materials Task Force Reports The mission of the Die Materials Committee is to conduct, support and direct research activities and disseminate the resultant information in order to advance the state-of-the-art of dies and shot sleeves. These efforts are targeted to increase die and shot sleeve life, reduce machine downtime, produce higher quality castings and reduce cost. Because of the size of these Videos, PowerPoint Presentations, and PDF files, some of these are loaded onto a separate Virtual Server Site for downloading (requires fast T1 connection) or all are available on a custom Badger Metal CD which can be obtained FREE by calling us with your request. These FREE password protected reports are only available through Badger Metal Tech, Inc. Request Login and Password Request the CD Four times a year NADCAs Die Material Committee meets to discuss and report on topics specific to die materials. The meetings usually last one full day. During that time task force committees present powerpoint slide presentations on the progress of their task force reports. There are basically five task force committees. This is leading edge technology and data. Case Western Projects for DOD and DOE Surface Engineering and Coatings Taskforce Die Materials Development Taskforce Die Materials Specifications and Heat Treat Taskforce Residual Stress Taskforce The following are specific topics discussed in each DMC report. To the right is a short definition of the material discussed. These are all presented in PowerPoint pps or Adobe pdf format. Download Powerpoint viewer f "); array_files[47]=new Array(0,1,"http://www.badgermetal.com/links.htm","2009-07-17","30K","Links to Other Sites ","",""," Links to Other Sites Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Die Casting Suppliers, Labs, & Die Casting End Users (Newly added - Career Finder Assistant This page was updated - July 12, 2009 Career Finder Assistant Die Casters Encyclopedia Lombness Tool Get er done - 24/7 Die Repair & Rework Cost effective solutions to materials related problems. Materials Testing Ultra Polishing Schaumberg, IL Quick Turnaround Pickup and Delivery IL and Milw. BodyCote Metal Evaluation Vobeda Machine & Tool Co. Make It Right The First Time Quick Search for Die Casters The Magazine Source Case Western Reserve University Net Shape Engineering Residual Stress Analysis Equipment & Services Colorado School of Mines Advanced Coatings and Surface Engineering Laboratory Precision Metalforming Association Using specialized Ultrasonics to effectively remove solder from die cast dies click on reel to download the database Hold the mouse pointer over reel to view movie count and last movie seen for month Download Jerry and Lauras 1* to 5* Ratings (1307) Movies). Listing for only Theater Attended movies. Updated monthly. Sorted 6 ways. Last Movie seen: The Proposal- June 30, 2009 Rating: Jerry 5**** Laura 4***** By Year then Title By Title By Year then Male Rating By Year then Female Rating By Male Rating then Title By Female Rating then Title (best viewed on screen - printed version 48x6 = 288pgs) Pause your mouse over the projector to see the count for last months movies. This Excel spreadsheet database was last updated and posted on 07/17/2009 . (Excel XP 2002 Format) file size 788K This file is zipped. You will need an unzipping program to view Back to Top Page was l "); array_files[48]=new Array(0,1,"http://www.badgermetal.com/ml%2Btl-combo/ml%2Btl-combo-pics.htm","2009-07-17","24K","Photos comparing physical Metallife and Thermallife in combination ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life,porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure,edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue,dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite ","close up view showing resulting coating finish using Metallife and Thermallife "," Photos comparing physical Metallife and Thermallife in combination Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Comparisons using Combinations of with The enlarged photos show how the 46Rc dies physical appearance is modified with various combinations. A View above return to die B View above return to die C View above return to die D View above return to die E view above - return to die F View above return to die The enlarged photos show how the 46Rc dies physical appearance is modified with various combinations. Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[49]=new Array(0,1,"http://www.badgermetal.com/players.htm","2009-07-17","31K","Badger Metal Management Team ","",""," Badger Metal Management Team Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Our Team of Players I am very concerned and firmly believe that China was a big contributor to the 2008 economic down turn and recession. We need to get back and maintain a secure and strong USA manufacturing base in this country. In 1860 Lincoln said Manufacture here WE get the goods and money. Manufacture abroad WE only get the goods. Draining a country of money is what makes it poor and weak Jerald (Jerry) Skoff - President Jerry started Badger Metal Tech Inc. in 1983, and since that time, more than 100,000 tools have passed through their facility in Menomonee Falls, WI. He has written numerous articles for the die casting industry, including papers for Die Casting Congresses and Die Casting Engineer magazine. His latest was a two part article on - Understanding Residual Stress Effects and Corrective Action for Die Casting Tools - which appeared in September 2007 and January 2008. He is considered an authority on die casting die residual stress and chaired a task force for the Die Materials Committee, which worked to establish baseline stress parameters for die cast tooling. Jerry has been with the company since it was started in 1983. He has seen it grow from a company doing business in Southern Wisconsin to one that has customers for end users of die castings in almost every state in the US. Badgers customer base now goes beyond our northern border into Canada and Quebec. Jerry continuously has his fingers and mind on the pulse of the company and industries to assure that Badger is keeping up with current technologies, but he still enjoys selling so dont be surprised i "); array_files[50]=new Array(0,1,"http://www.badgermetal.com/ml%2Btl-combo/ml%2Btl-combo.htm","2009-07-17","36K","Comparison of surface and die improvement using Metallife and Thermallife in combination ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life,porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure,edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue,dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite ","coating combinations for die casting tooling using only Metallife and Thermallife "," Comparison of surface and die improvement using Metallife and Thermallife in combination Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Surface Comparisons using Combinations of and The above photo of a die casting die shows sections that were processed with different combinations of our MetaLL ifeŇ and TherMaLLifeŇ processes. The letters indicate areas that can be viewed in a close up view. Click on any letter to see the corresponding view. Click here...to see crack closure results. The enlarged photos show how the 46Rc dies physical appearance is affected with various combinations. The chart below provides reasons why you might choose a particular combination. Process Combination Reason and Justification to Apply MetaLL ifeŇ then TherMaLLifeŇ - New Die Durability of topography benefits - Cavitation/Lamination MetaLL ifeŇ then TherMaLLifeŇ then MetaLL ifeŇ again Proactive die maintenance program - Guarantee TherMaLLifeŇ then MetaLL ifeŇ - New Die Maximum protection and cosmetic requirement All applications could be polished or buffed to a chrome application finish. No additional time or procedure change in polishing or buffing was necessary. Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[51]=new Array(0,1,"http://www.badgermetal.com/core-w-tl-and-ml.htm","2009-07-17","25K","Actual cores treated with combinations of Metallife and Thermallife ","",""," Actual cores treated with combinations of Metallife and Thermallife Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Back to Previous Combining with #1 - MetaLL ifeŇ applied prior shows topography #2 - MetaLL ifeŇ applied after no topography or spalling Compression Curves Diffusion Layer Back to Previous Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[52]=new Array(0,1,"http://www.badgermetal.com/nitriding-control-article/fnc-article-sh/controlling-nh3-dissociation.htm","2009-07-17","49K","New method for controlling ammonia gas dissociation ","",""," New method for controlling ammonia gas dissociation Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Link to Original Industrial Heating Article Gas Nitriding Measurement Technology Advancements Relationship to Tool Steels A new advanced control system for measuring ammonia dissociation has been developed which allows for improved repeatability and precise parameter adjustments. The above link contains the complete article.Nitriding and nitrocarburizing are surface treatements intended to increase surface hardness and to improve other properties steels including tool steels. One of the appealing attributes of the lower temperature TherMaLL ifeŇ nitrocarburizing (FNC) process is that rapid quenching is not required; hence, dimensional changes are kept to a minimum. Benefits include: Exceptionally high surface hardness Resistance to wear, anti-galling properties (good in poor lubricating conditions), and the reduction of soldering tendencies in die cast and aluminum extruding operations. Minimal distortion and deformation compared with carburizing/hardening The lower processing temperature eliminates hardness changes in hot work steels such as H-13. Improved fatigue life and other fatigue-related properties such as fatigue strength (resistance to dynamic loading) Small volumetric changes (some growth does occur) The follow are some photos, graphs, and schematic excerpts from orginal article Innovative commercial heat treat companies are improving furnace atmosphere control by adapting state-of-the-art temperature and atmosphere controls, which provide continuous, precise regulation of the process in progress (Fig 1). Fig 1 - Modern gas nitrocarburizing "); array_files[53]=new Array(0,1,"http://www.badgermetal.com/services-badger-metal.htm","2009-07-17","21K","Metallife service for die casting dies plastic molds and drawing forming blanking tooling ","heat checking, fatigue cracking,breakout from cavitation, Metallife, Thermallife, Metalife, Thermalife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue,dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, reduce die casting scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, Metal life, Metal life process, metallife process, die casting surface treatments, die surface treatment, die surface engineering, metal life surface treatment, die lube, die lubricant, die casting lubricant, die lubricity, lubricity, shot peening, metallife peening, die shot peening, peening, laser peening, precision peening, precision peening process, precision shot peening, precision shot peening process, residual stress, controlled residual stress, compressive stress texturing, controlling residual stress, reducing residual stress, residual compressive stress, compressive stress, surface compression, weld peening, weld shot peening, cycle failure, surface coating, die casting coating, coating process, die surface coating, mechanical coating, mechanical coating process, casting porosity, breakout, die breakout, diamond polishing, diamond polish, flash, flash reduction, reduced flashing, flashing, gross cracking, NADCA, North American Die Casting Association, shot blasting, abrasive blasting, blasting, stress relief, ion bond diffusions, solder of die casting dies, blistering, blast sand blast cleaning, ","Metallife Metalife Metal Life service of compressive stress texturing to improve the performance and extend the life of die casting dies plastic molds and drawing forming blanking stamping dies "," Metallife service for die casting dies plastic molds and drawing forming blanking tooling Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[54]=new Array(0,1,"http://www.badgermetal.com/pct-broch-2.htm","2009-07-17","28K","Perishable Cutting Tool brochure-page2 ","",""," Perishable Cutting Tool brochure-page2 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com click on arrow to continue Today’s modern manufacturing methods demand extremely high productivity levels with as little downtime as possible. The MetaLL ifeŇ surface treatment provides a means for attaining this as well as helping to reduce manufacturing tooling costs. WHAT IS IT? MetaLL ifeŇ utilizes a well known principle of metallurgy regarding compressive stress layer generation in metals. Such a layer tends to reduce fatigue failure, and help retard or prevent crack initiation and propagation. The MetaLL ifeŇ treatment involves impacting a tooling surface with a controlled micro media to induce a beneficial compressive stress layer on the surface of the steel. Three important changes occur as a result. ENCAPSULATING RESIDUAL LAYER - The generated compressive stress layer slightly work hardens the tool while replacing the normal surface tensile stresses that are left in a tool after sharpening or finish grinding thus making the tool more resistant to fatigue cracking. MOST EXISTING GRAIN BOUNDARIES ELIMINATED - The impaction of the tool helps obliterate most of the grain boundaries and stress risers which then prohibits micro-cracks from initiating or propagating in these areas. It is these cracks that lead to tool chipping or edge breakdown. ADDITIONAL COOLANT RESERVOIRS - At the time of surface impaction, tiny microscopic pockets are created that act as coolant reservoirs. These pockets trap lubricant, thus allowing a cooler operating temperature which helps extend tool life. The documented test results on the accompanying page indicate what some of our cus "); array_files[55]=new Array(0,1,"http://www.badgermetal.com/careers.htm","2009-07-17","23K","helping others find jobs and careers ","",""," helping others find jobs and careers Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Helping Others Find Jobs and New Careers Contact Information If you are looking for good people Paul Johnson - Retired PHB Die Cast Consulting Posted 06/30/2008 Back to Top Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[56]=new Array(0,1,"http://www.badgermetal.com/lambda-coupons-dfs.htm","2009-07-17","28K","Coupons used for plotting compression curves - Drawing Forming ","",""," Coupons used for plotting compression curves - Drawing Forming Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Why do we use Lambda to measure values? Curves and Graphs for tool steel Compressive Stress + Nitrocarburizing = Longer Tool Life & The compressive stress factor of MetaLLifeŇ offers an increase of 30-40% of the effective yield strength of tool steel. When combined with our TherMaLL ifeŇ nitrocarburizing process, tooling has then both fatigue and wear resistance. TherMaLL ifeŇ is not recommended for D-2 unless final temper was done at above 1000 degrees F. The microstructure of a ferritic nitrocarburized H-13 surface shows an epsilon compound layer that is .0002 to .0008 in depth followed by the sub-surface diffusion zone (carbon/nitrogen) ranging in depth from .004 to .008 (dependent on processing criteria) which gradually dissipates. Click on coupon to view a section Click on coupon to view a section Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[57]=new Array(0,1,"http://www.badgermetal.com/bmtcastg.htm","2009-07-17","33K","Badger Metal Casting 2000 - Front H-13 and Back P-20 ","",""," Badger Metal Casting 2000 - Front H-13 and Back P-20 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Badger Metal Casting 2000 NEW Sample MetaLL ifeŇ aluminum casting from 47-48Rc die casting insert Request Casting/sWe are pleased to advise that we can now supply you with Badger Metal Tech – MetaLL ifeŇ - aluminum casting samples showing the 10 processes that we currently supply to the die casting industry on a sample specimen actually made from a treated die casting die. These castings reflect the various topographies that may be expected based on a 47-48Rc tool steel hardness since they were cast with a die having the respective hardness. The cover side of this tool (compressive topography side) was made from H-13 material while the ejector side (MetaLL ifeŇ Logo side) was purposely produced from P-20 material. A visual examination will show how rapidly this run of only 5000 pcs has caused heat checking to develop on the P-20 side which was not MetaLL ifeŇ protected. double click on a photo of the casting or the die to see a larger view casting from H-13 cover side of die casting from P20 side of die The T-41 and T-41H are the most requested processes. The T-40H and T-41H spec on this casting was developed for those instances where a very high degree of compression and depth are desired. This also results in significant topography to the die even at 47-48Rc. Not all die configurations will lend themselves to this high intensity process. We encourage you to show these sample castings to your customers or use them to help determine your future MetaLL ifeŇ requirements. You can paint, polish, buff, or finish them to determine which T process would be "); array_files[58]=new Array(0,1,"http://www.badgermetal.com/requests.htm","2009-07-17","41K","Request and General Information ","",""," Request and General Information Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Badger Metal Tech, Inc. - N60 W15088 Bobolink Ave. - Menomonee Falls, WI 53051 FAX 262-252-3956 Jerry Skoff Matt Werner Marvelle Chapman jskoff@badgermetal.com mwerner@badgermetal.com mchapman@badgermetal.com 262-252-3804 800-366-1973 26 slide Power Point presentation Download 18 slide Power Point presentation 2ea 3 min streaming videos Download 15 slide Power Point presentation Download 9 slide Power Point Printed Information NADCA Report Links Pricing, Delivery, Certifications Specifications FAQs, etc. *RequiredInformation Contact Name: Your Name First Last Title * ** Company Name: * Address 1: * Address 2: City: * State: ? AL AK AZ AR CA CO CT DE DC FL GA HI ID IL IN IA KS KY LA ME MD MA MI MN MS MO MT NE NV NH NJ MN NY NC ND OH OK OR PA PR RI SC SD TN TX VR UT VT VA WA WV WI WY *USA Zip/Postal Code: *Country: ? U.S.A. Canada Mexico Australia France Germany Other Phone + Ext: * Direct Dial number preferred Fax: * Toll Free: If you have one E-mail: or enter none * If you would like to be added to our emailed newsletter list which is mailed bi-monthly, re-enter your complete email address below. Return to top Please use the comment box below to request specific information or for questions: If you would like us to link your Web URL on our links page, please include your full URL information. Please allow 1 week after final approval for posting. Return to top If you need additional information other than what is found on our website, please take a moment to sign our guestbook, and check off any information you would like to receive by fax, or mail. Protection of Privacy "); array_files[59]=new Array(0,1,"http://www.badgermetal.com/quoterequest-dfs.htm","2009-07-17","57K","Quote RFQ Drawing Forming Blanking ","",""," Quote RFQ Drawing Forming Blanking Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files return to themallife home page for draw forming / blanking DRAWING/FORMING/BLANKING RFQ Submit this form if a drawing is not available Click here to use the short form if a casting is being sent Badger Metal Tech - Request for Quote MetaLL ifeŇ and/or TherMaLLifeŇ Use this form to email us your tooling requirements along with any necessary drawings and photos. Use the tab key to jump from field to field MetaLL ifeŇ is priced based on surface area processed TherMaLLifeŇ is priced based on total weight of the lot Items marked with a red (*) are required fields Customer Information - Quote or RFQ # Metallife None - Thermallife None Date Quote Needed When should we follow-up? How many days can tooling be out of production? 1 work week 1 2 3 4 5 2 work weeks 3 work weeks or more * Will you need Accelerated Delivery? No Yes * (normal delivery is 1-2 days for TherMaLLifeŇ and 3-5 days for MetaLL ifeŇ) Approximate Ship Date to Badger if approved Company Name: * Person Requesting Quote: * Client Customer: * if not known enter ? Part # * if not known enter ? Part Name * if not known enter ? Description * if not known enter ? Dimension and Weight Information Tooling dimensions are in inch mm Please specify here. Tooling weights are in lbs kilos use this handy conversion link if needed For - TherMaLLifeŇ (include steel type identification form) Approx Weight (lbs) of All Insert, Slides, Cores, Etc. Total number of pieces Steel Type D2 A2 M? other Maraging H-13 Premium H-13 (this information is mandatory) (if only TherMaLLifeŇ is requested, jump to bottom of this form Continue here for MetaLL ifeŇ Number of Draw or Blanking Dies ? 1 2 3 4 5 6 7 8 other * if other Die Max Length * Max Width * Max Height * Appro "); array_files[60]=new Array(0,1,"http://www.badgermetal.com/glossary.htm","2009-07-17","49K","A glossary of terms commonly used in the tooling industry ","heat checking, fatigue cracking,breakout from cavitation, Metallife, Thermallife, Metalife, Thermalife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue,dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, reduce die casting scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, Metal life, Metal life process, metallife process, die casting surface treatments, die surface treatment, die surface engineering, metal life surface treatment, die lube, die lubricant, die casting lubricant, die lubricity, lubricity, shot peening, metallife peening, die shot peening, peening, laser peening, precision peening, precision peening process, precision shot peening, precision shot peening process, residual stress, controlled residual stress, compressive stress texturing, controlling residual stress, reducing residual stress, residual compressive stress, compressive stress, surface compression, weld peening, weld shot peening, cycle failure, surface coating, die casting coating, coating process, die surface coating, mechanical coating, mechanical coating process, casting porosity, breakout, die breakout, diamond polishing, diamond polish, flash, flash reduction, reduced flashing, flashing, gross cracking, NADCA, North American Die Casting Association, shot blasting, abrasive blasting, blasting, stress relief, ion bond diffusions, solder of die casting dies, blistering, blast sand blast cleaning, ","glossary of common terms used in die casting dies and other tooling and mold materials ","Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Glossary Abrasive Blasting The process by which loose abrasive is propelled at high velocity, via air or wheel. Annealing Annealing applies to softening by changing the microstructure and is the term used to describe the heating and cooling cycles in a solid state. Balzers, Phygen, Ion Bond, Melonite, Philo Popular coatings that may be applied over either Metallife or Thermallife substrate where considered necessary Blast, Sand Blasting Cleaning Abrasive blast cleaning using sharp edged media for removing debris, oxides, and other surface contaminants. Will invariably set us stress risers that lead to shortened tool life and premature failure by fatigue of the surface Blistering See Laminar Fill or Porosity. Breakout, Die Breakout Excess metal protruding from a casting resulting from cracking or pitting of a molding surface such as a die casting die or plastic injection mold. Is usually result of unchecked die cavitation effect Case Hardening Diffusion and/or heat treatment method that adds high carbon in a very thin surface layer that increases strength and some brittleness to OEM parts. Not usually used on tool steels which prefers a nitriding or carbonitriding hardening method of diffusion Castings Object obtained by pouring molten metal in a mold; also the act of pouring metal. Materials include: aluminum, magnesium, zinc, gray iron, malleable iron and steel. Casting Texturing A specific texture applied to castings to accomplish a change in cosmetic finish for appearance or to improve the flow of metal in a die casting operation in specific areas or the entire die. Often times combined with compres "); array_files[61]=new Array(0,1,"http://www.badgermetal.com/laserlife/laserlife.htm","2009-07-17","23K","Laser peen testing at Case Western for die casting dies ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life,porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure,edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue,dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite ","New advancements in applying Metallife by laser peening "," Laser peen testing at Case Western for die casting dies Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com To download a longer version or view other movies and presentations Request Login and Password Laser Technology- See it here! 1min clip clip Using Lasers to induce Compressive Stress Windows Media file Requires Media Player click on photo to view larger photo and comparison graph Note the waffled surface created by the laser impaction. This specimen was evaluated by Case Western Reserve University Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[62]=new Array(0,1,"http://www.badgermetal.com/laserlife/laserlife-test.htm","2009-07-17","25K","Laser peen testing at Case Western for die casting dies shows 4 times the compression fatigue resistance ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life,porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure,edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue,dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite ","graphs showing laser peening effect to die casting tooling "," Laser peen testing at Case Western for die casting dies shows 4 times the compression fatigue resistance Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Compressive Stress Comparison Opposite side was standard shot peened 2 data anomoly points indicated This specimen was evaluated by Case Western Reserve UniversityThe industry over the past 22 years has come to know the benefits of compressive stress to help fight steel fatigue. The MetaLLifeŇ process is the accepted method of choice for extending the life of perishable tooling that fails due to fatigue or thermal fatigue. Now on the horizon rises a new star.After 3 years in laboratory and development research, Laser peening has successfully emerged as a viable commercial technology. The compressive residual stresses that are created are approximately 4 times that of conventional peening. Although still in its infancy due to high costs, commercial aerospace applications such as in the aviation sector, have found a ROI that justifies a laser peening process and technology. Laser peening (Laser*Life for tooling) involves impinging an intense beam of light on an ablative surface. The shock wave created by the laser beam impresses a deep but highly controlled level of residual compression into specific applied areas of the selected material without any heat. These compressive values and depth are 4 times those of conventional methods.The basics of laser peening involve an ablative thermal insulating layer, water, and a beam that has roughly a 25J at 25 ns output from a Nd:glass laser. The area to be processed is covered with an ablative thermal insulating layer. The leading temporal edge of the laser im "); array_files[63]=new Array(0,1,"http://www.badgermetal.com/news-techtip.htm","2009-07-17","31K","Newsletter Computer Tech Tip ","",""," Newsletter Computer Tech Tip Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Welcome To Our Tech Tip Contents In each or our newsletter issues, we offer a quick tip that will make your relationship with computing less stressful click on the below for our Newsletter Computer Tech Tip June 2009 - Need a business phone number - Use FREE Google Info - 1-800-goog411 (1-800-466-4411) Try It! March 2009 - Browse Internet Explorer History using your mouse wheel December 2008 - Login to XP and not require a password or login September 2008 - PDF Free PDF reader and Free creator June 2008 Software - Backup your Windows Registry - Tech Tip.....See all the details in Windows Explorer March 2008 Software - Defragment all your drives with one click using JKDefrag - NO installation and FREE December 2007 Software - Easy Resize Photos for Emailing September 2007 Emailing Large Files June 2007 Using FoxFire Browser March 2007 Software - Home Page Conversion Program - Freeware January 2007 Using Excel to Send Photos September 2006 Software - Maximize Internet Explorer Window.... Tech Tip - Do it without software May 2006 Close Down and Stop Popups Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[64]=new Array(0,1,"http://www.badgermetal.com/pct-broch-3.htm","2009-07-17","21K","Perishable Cutting Tool brochure-page3 ","",""," Perishable Cutting Tool brochure-page3 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com click on left arrow Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[65]=new Array(0,1,"http://www.badgermetal.com/calendar.htm","2009-07-17","21K","Badger Calendar 2008 ","",""," Badger Calendar 2008 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Badger Calendar for 2009 If you are currently on our mailing list or a valued customer, we will be sending you in December our Badger Metal calendar for Wisconsin, Illinois, or Minnesota depending on your city. Supplies are limited, so if you want to be included, send us an email requesting one. Just click on the email below to send Paul Bartelak a request email. infonow@badgermetal.com The backing of the calendar illustrates the effect of trapped gases in your moltern metal and these trapped gases effect on breakout and lamination. MetaLL ifeŇ gets rid of these gases that causes premature destruction of your die tooling. Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[66]=new Array(0,1,"http://www.badgermetal.com/nitriding/carburizing-types.htm","2009-07-17","21K","Carburizing Types ","",""," Carburizing Types Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Types of Nitriding Index to types of nitrocarburizing methods Nitriding and Nitrocarburizing Nitempering Controlled Nitrocarburizing Soft Nitriding Triniding Nitroc Process Vacuum Nitrocarburizing Nitrotec Process Austenite Nitrocarburizing Nitriding and Nitrocarburizing With the use of external heating or submerged-combustion heating, the atmospheres used in conventional furnaces can also be used. Some of the advantages of FNC treatments include: Reduced cycle times Faster recovery rates Rapid changes of atmosphere compositions Its primary disadvantage is the volume of reactive gas needed to fluidize the bed. To improve operating efficiencies and reduce cost it is necessary to increase the depth of the bed which increases its volume and reduce the required gas flow. The TherMaLLifeŇ process meets this efficiency at a depth of 48 inches. back to types Other Types Nitempering Usually carried out in sealed quench furnaces, uses an inlet atmosphere consisting of 50% ammonia and 50% endothermic gas. Tempering temperatures 1060 degrees F. Treatment times between 1-3 hours. Quenching by oil or cooling with recirculating protective gases. Nitemper has been in use since the early 90s. Mostly done in Germany, Sweden, USA, Japan, and the United Kingdom. back to types Controlled Nitrocarburizing This type of nitriding overcomes some of the limitations of Nitempering by introducing infrared monitoring and a control system. Controlled nitrocarburizing can take account not only of variable loads and materials but can also provide reproducible component growth characteristics. The treatment involves processing in an atmosphere with a predetermined nitriding and carburizing potential and controlling the nitrocarburizing potential "); array_files[67]=new Array(0,1,"http://www.badgermetal.com/nitriding/bed-and-furnace-criteria.htm","2009-07-17","38K","Nitro-carburizing bed criteria ","",""," Nitro-carburizing bed criteria Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com FNC Criteria The FNC Phenomenon Gas velocities v/s temperatures Heat transfer factors Gas composition & percentages Summary The FNC Phenomenon Fluidization, contrary what you may be led to believe, is not a new technology. An 1879 patent discusses baking minerals under bed conditions and draws attention to the outstanding uniformity of temperature it affords. Fluidization consists of making a bed of dry finely-divided particles, usually aluminum oxide, behave like a liquid. This is accomplished by moving gases through the mediums particles which separates them microscopically as the gases are fed through the bed. The majority of beds used for heat treatment are of the aggregative or bubbling bed type. The smooth or bubbly properties of the solids and fluids will determine the fluidization quality. On the other hand, the size of the bubbles and heterogeneity in the bed influences the rate of solid mixing. These factors include bed geometry, gas flow rate, type of gas distributor, and internal vessel features such as baffles, screens, and heat exchangers. It can easily be seen that the success of fluidization, carbonitriding, and quality of treatment is influenced by many needed control factors. TherMaLLifeŇ has these controls.. back to top Gas velocities v/s temperatures If you plunge your hand into a fluidized bed medium (preferably one that is not heated), the sensation is the same as placing your hand in a bucket of water. When an aluminum oxide medium is fluidized in a bed, and a light object is introduced in the bed, it will float, the same as in a liquid. The require "); array_files[68]=new Array(0,1,"http://www.badgermetal.com/nitriding/micro-photos.htm","2009-07-17","21K","Microstructure Ferritic Nitrocarburized ","",""," Microstructure Ferritic Nitrocarburized Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com These micro hardness photos show the compound zone and the diffused layer created in the TherMaLLifeŇ nitrocarburizing process . Gases - N2, NH3, CH4 The compound layer can have a depth of 5-20 microns = .0002-.0008 inches The sub-surface diffused layer ranges from 102-203 microns = .004-.008 inches Carbon 4150 steel treated at 700 oC for 2hrs in an atmosphere of 49% N2, 50% NH3 and 1% CH4. Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[69]=new Array(0,1,"http://www.badgermetal.com/nitriding/nitriding-history.htm","2009-07-17","26K","History of Nitriding ","",""," History of Nitriding Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com History of Nitriding The early pioneering work of Fry, Machlet, as well as others Dr. Adolph Fry in the early 1900s found that nitrogen and iron had an affinity to one another, much the same way that aluminum and iron contact under heat can cause soldering to occur in die casting dies. From his work in 1906 he developed the iron-nitrogen equilibrium diagram. This diagram is still valid today. If heat is applied to both iron and a nitrogen gas, the nitrogen will diffuse in the surface of the steel and along with this create a structural change in the surface of the steel affecting the hardness. This increase, it was noted, went from 282 Brinell hardness to 470 Brinell in steel containing .39% carbon and 2.88 % chromium. From this began the development of extremely high surface hardness steels called Nitralloy steels. These steels provided high resistance to decomposition along with being stable to temperatures up to 1800 degrees F. Dr. Fry also investigated the effect of adding other alloys such as vanadium, tungsten, manganese, molybdenum, and titanium and discovered that all of these elements would also produce stable high nitrogen content nitrides. At the same time in New Jersey, Adolph Machlet while working for American Gas Company in Elizabeth, was also studying absorption of nitrogen into iron under heat conditions. He applied for his patents somewhat earlier than Fry. He consequently received his patent long before Fry on June 24, 1913. Sad to say no commercial benefits were recognized by US industries at the time, however, Dr. Jeffries in Essen Germany saw otherwise and push "); array_files[70]=new Array(0,1,"http://www.badgermetal.com/nitriding/table-of-diffusion-applications.htm","2009-07-17","27K","Table of diffusion properties ","",""," Table of diffusion properties Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Tooling Applications & Benefits Obtained Hot Work Tool Steels Cold Work Tool Steels Die Cast Dies Thermoset Plastic Molds - H-13 Hot Forging Dies Cold Forging Dies Extrusion Tools Drawing Forming Blanking Dies Wear Resistance Indentation Resistance Increase Fatigue Strength No Surface Finish Topography No Line of Sight Limitation Dimensional Control back to topics Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[71]=new Array(0,1,"http://www.badgermetal.com/nitriding/automation-benefits.htm","2009-07-17","33K","Benefits of using automation ","",""," Benefits of using automation Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Automation Benefits A properly controlled atmosphere with dissociation monitoring allows tools to be heated or cooled at rates that are very close to those obtained in a conventional salt or lead bath environment without suffering the distortion or contamination side effects. As discussed in our section - FNC criteria, to obtain a repeatable and controlled nitrocarburizing procedure, it is imperative to have properly controlled heat transfer criteria to assure successfully completing the entire process. Five factors have been established as being the most critical for tooling applications. Cleanliness of the tool steel Particle diameter Bed material density Fluidization velocity of the gas/gases Temperature controls Let us examine these one at a time. Cleanliness of the tool steel First and foremost is the cleanliness of the part or tool steel. Usually a mild to aggressive alkaline bath at elevated temperature is recommended to remove both water and oil base materials on the surface and any other areas that will contact the bed media.. If these trace elements are not entirely removed the nitrocarburizing is compromised. In addition the bed media is also contaminated that jeopardizes subsequent batches in the bed. For these reasons it is important to ask and know how the tools are cleaned prior to processing. Our automated process includes and automatic first station alkaline bath and dry treatment at elevated temperature (below 212 degrees F) for a predetermined amount of time depending on the load. back to menu Particle diameter The diameter of the aluminum oxide particles "); array_files[72]=new Array(0,1,"http://www.badgermetal.com/nitriding/curves-photos-micro.htm","2009-07-17","22K","Thermallife curves,graphs,photos,micro ","",""," Thermallife curves,graphs,photos,micro Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Test Coupons - Curves Microstructure - Relational Curves back to previous Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[73]=new Array(0,1,"http://www.badgermetal.com/nitriding/tl-discuss.htm","2009-07-17","27K","Discussion of Nitrocarburizing ","",""," Discussion of Nitrocarburizing Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com A special thank you to Ray W. Reynoldson for permitting us to use information from his book and literature Heat Treatment in controlled atmosphere Furnaces From this page you can go to more in depth topics. If you lose your way, simply click on the main icons at the top of this and every page. back to thermallife Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[74]=new Array(0,1,"http://www.badgermetal.com/nitriding/nitro-carburizing.htm","2009-07-17","23K","Ferritic Nitrocarburing Definitions ","",""," Ferritic Nitrocarburing Definitions Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Definitions Ferritic Nitrocarburing Definitions & Descriptions Thermochemical diffusion process where nitrogen, carbon, and to a very small degree, oxygen atoms diffuse into the surface of the ferrous substrate forming a compound layer and subsurface diffusion layer. Objectively the diffusion is accomplished in a relatively short period of time and at subcritical temperatures. The resulting white cast or epsilon layer and subjacent diffusion layer enhances the performance characteristics of the base metal material. The primary objectives Improve wear properties Corrosion resistance Improve fatigue characteristics of the metal. Reduce soldering of die cast dies and associated components. Nitrocarburizing requires a source of carbon, and nitrogen Simple nitriding can be done in a gas, liquid salt, or plasma (electrically charged ions) environment. Fluidized Bed Nitrocarburizing Less controllable Advantages over Gas and Salt methods Reduced Cycle Times Faster Recovery Rapid changes of atmosphere compositions Disadvantage - media contamination of water lines and orifices Historical Prominent Developers Salt Bath Nitrocarburizing About 50 years ago commercial methods of ferritic nitrocarburizing in molten salts came into existence on a commercial basis. The first process in France was called Sulfiniz and used cyanide and cyanates salts plus a small amount of sulfur bearing compounds. In 1959 a modified version patent from Germany was filed for an aeration oxygen source which was called Tufftride. The 1970s EPA regs impacted the cyanide based materials and new salt composi "); array_files[75]=new Array(0,1,"http://www.badgermetal.com/nitriding/relation-curves.htm","2009-07-17","23K","Relational Curves for nitro carburizing ","",""," Relational Curves for nitro carburizing Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com TherMaLLifeŇ Microstructure Hardness Curve The compound layer can have a depth of 5-20 microns = .0002-.0008 inches The diffused layer can range from 102-203 microns = .004-.008 inches diffused 1 micron = .0000394 Relationship of Heat Transfer, Gas Velocity, and Temperature Effect to TherMaLL ifeŇ bed Fluidization Back to topics Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[76]=new Array(0,1,"http://www.badgermetal.com/nitriding/table-diffusion-treatments.htm","2009-07-17","32K","Table of Currently Used Diffusion Surface Treatment ","",""," Table of Currently Used Diffusion Surface Treatment Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Comparison of TherMaLLifeŇ to standard nitriding treatments (see bottom of chart for depth conversions & legends) TherMaLLifeŇ Standard Nitriding Surface Layer FNC Iron Nitride Method of Application V or Atmos* #G,S,P,V,F/B* Surface Temperature degrees C 482-649 (560 opt) 500-550 Surface Temperature degrees F 900-1200 (1040 opt) 932-1022 Core Temperature degrees C 482-649 (560 opt) 505-550 Core Temperature degrees F 900-1200 (1040 opt) 932-1022 These temperatures are minimum to the maximum ranges for all steels. DievarŇ by Uddeholm has special time/temp recipe. Actual Control temperatures are at least 50 degrees F below final steel temper specification - i.e. - If final temper for H-13 is standardized at 1100 degrees F, FNC would be at most 1050 or below this. Duration (hrs) 1-8 6-72 Compound Thickness (microns)* 5-20 (6-8 opt) n/a Compound Thickness (inches)* .0002-.0008 (2-3 opt) n/a Diffused Layer (microns)* 102-203 (100-120 opt) 90-160 Diffused Layer (inches)* .004-.008 (4-5 opt) .003-.006 Hardness VHN - 10 grams load (compound layer) (65 file hardness) 700-1000 Hardness VHN - 500 gram load (diffusion layer) 1200-1500 (65 file hardness) n/a Equivalent Hardness Rc (150 kilogram load) compound+diffusion+base 65-70Rc n/a Distortion n/a n/a Sectional Coating Yes Yes Base Material Treatment Before Treatment Before Treatment Post Processing Rarely Rarely Thickness Uniformity Excellent Good Parent Material Metals Metals (Compound Layer also called white or epsilon or ceramic layer) (Cleaning) # Method Used = G=Gas, S=Salt, P=Powder, V=Vacuum, F/B=Fluidiz "); array_files[77]=new Array(0,1,"http://www.badgermetal.com/news.htm","2009-07-17","85K","Die Casting resource newletters for topics relating to die casting dies and die materials ","",""," Die Casting resource newletters for topics relating to die casting dies and die materials Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Welcome To Our News Section for: & 2008 Newsletters Scroll down for the latest information MetaLL ifeŇ TherMaLLifeŇ Customer testimonies and Case studies Success studies are in Power Point slide show format Badger Newsletter Archives - 1994-2009 Since 2006, we have included in each newsletter Computer TechTips on everyday nuisances involving computers. This button takes you to a Table of Contents for these Computer TechTip . Or click on the below. 2009 - BADGER METAL - Emailed newsletters March 2009 - Las Vegas Die Casting Expo Congress Success Stories(panel discussion of various success stories using various types of die maintenance and repair procedures) Browse Internet Explorer History using your mouse wheel 2008 - BADGER METAL - Emailed newsletters December 2008 - Let Badger Metal Track Your Die Maintenance Historical Data (catastrophic failure of die cast tooling that usually requires replacement of the failed component) Logon to Windows XP without a password or login. September 2008 - Gross Cracking - A Hard to Quantify Failure Mode (catastrophic failure of die cast tooling that usually requires replacement of the failed component) PDF Free PDF reader and Free creator June 2008 - Supplier Excellence - How We Resurrected Retired Tooling (A case study in supplier excellence and polishing effect to processed tooling) Software - Backup your Windows Registry - Tech Tip.....See all the details in Windows Explorer March 2008 - Improve Flow and Reduce Lamination with a Permanent Topography (After Metallife topograph "); array_files[78]=new Array(0,1,"http://www.badgermetal.com/main-dfs.htm","2009-07-17","30K","Badger Metal Tech - Home Drawing Forming Blanking ","=metalife, metalife, metalife, metalife, metalife, metallife, metallife, metallife, thermallife, thermallife, thermallife, thermalife, thermalife, theremalife, metalife compressive stress, compressive stress, topography, diecast, die casting, stamping dies, stamping tools, stamping tooling, drawing dies, drawing tooling, forming dies, forming tooling, extruding dies, extruding tooling, tool protection, tool protection, tool protection, lubricity, lubricity, lubricity, tool life, tool life, edm, electrical discharge machining, wire edm, thermal, thermal stress, heatchecking, heat checking, heat check, stress temper, stress relieve, washout, erosion, thermal shock, tool life, soldering, sticking, metallife, metallife, movies, metal life, meta life, metallife, micro peening, peening, diffusion process, ferritic nitro-carburizing, diffusion, ferritic nitrocarburizing, nitriding, nitriding, nitriding, tufftride, tufftride ","=Metalife and Thermallife are not coatings or plating processes but proprietary compressive and fnc surface treatments for New and Used die casting and H-13 plastic tooling that closes existing heatcheck cracks in die casting dies, along with retarding the development of new cracks. Metalife also reduces the interactive soldering effects of aluminum metal to hot work steel dies. Stamping-Drawing-Forming tools also benefit by reducing galling and pickup along with preventing the edge breakdown of blanking tooling "," Badger Metal Tech - Home Drawing Forming Blanking Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files The future in Laser Technology Prevent fatigue with click on photo Drawing / Forming / Blanking Serving the Tool & Die Industry since 1983 N60 W15088 Bobolink Ave. Menomonee Falls, WI 53051 Stop galling with click on photo MetaLLifeŇ TherMaLLifeŇ Other beneficial Information Proquis and AllClear Business Management Software Measurement Conversion Program (Free) - Screenview Build your FlowCharts Analyse Data in Minutes vs Hours Some pages on our site were last updated July 07, 2009. If a page have been revised, it will be so indicated at the bottom. Copyright © 2003-2006 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. The Badger Metal Tech and MetaLL ifeŇ and TherMaLLifeŇ registered trademarks of Badger Metal Tech, Inc. as well as the complete intellectual property and graphics as so here published. Should you find problems with this site or broken links, please contact our webmaster webmaster@badgermetal.com Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[79]=new Array(0,1,"http://www.badgermetal.com/ml-dc/o-ring-grooveseals.htm","2009-07-17","23K","Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","Preventing heat check and thermal fatigue in seal grooves of die casting dies "," Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Examples of typical Seal Groove Applications Return to Stops Heat Checking Page The below photos show processing of o-ring and/or seal grooves on the ejector side of critical dies whose components provide sealing when matched together. Sometimes the cover side of the die has the sealing groove. Since stress risers occur on both the raised or grooved side of the sealing area, it is recommended to MetaLL ifeŇ process both halves. Processing of only the standing o-ring groove of front engine cover. Customer for this application was concerned about heat checking for the entire casting surface. Had tried welding previously without success. O-rings or sealing material can be damaged if casting risers exist in these areas. Return to Stops Heat Checking Page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[80]=new Array(0,1,"http://www.badgermetal.com/ml-dc/faqml-dc.htm","2009-07-17","92K","Metallife and Thermallife frequently asked questions for extend die casting die life and improving performance of die casting dies and other molds. ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","Frequently Asked Questions (FAQ) on various aspects of Metallife and its application to die casting dies "," Metallife and Thermallife frequently asked questions for extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Die Casting Frequently Asked Questions Print Newsletter on this topic Compressive Stress benefits of applying MetaLL ifeŇ after TherMaLLifeŇ to NEW tooling validated by Lambda labs. click on photo back to benefits Here are some facts regarding MetaLL ifeŇ that should answer common questions relating to our surface treatment. MetaLL ifeŇ is unique in that it is the only surface treatment capable of closing thermal heat check cracks. It is available since 1983, only from Badger Metal Tech, Inc. in Menomonee Falls, Wisconsin. Our certificate of compliance assures your satisfaction. Make sure you request this when placing your order. Applying to New tooling Painted castings Topography v/s drag Application to welds Previously hardened surfaces Topography v/s prior etching Badger Metal sample castings Runner/gate, partial processing Thermal transfer coefficient Coatings and diffusion processes Still see heat checks Tooling Dimension and Tolerance Changes Exceeding increased fatigue resistance Stress relieving methods Magnesium Casting Porosity Topography of the dies surface Questions/Topic Response How does the topography of the surface quality of MetaLL ifeŇ help me? In addition to trapping lubricant which helps casting release and improves metal flow, 2006 studies by Case Western University show that lubricant retention helps to increase die life. The residual die lubricant film insulates the surface of the die from direct contact with the molten metal thus low "); array_files[81]=new Array(0,1,"http://www.badgermetal.com/ml-dc/stops-dc.htm","2009-07-17","37K","Metallife and Thermallife stops cracking in die casting and improves performance of die casting dies and other molds. ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","Only Metallife can close stress cracking and stop pitting breakout in die casting dies "," Metallife and Thermallife stops cracking in die casting and improves performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Stops Thermal Stress Cracking & Pitting Breakout Heat Checking on the die Before & After Photos Photos of Before and After on NEW and USED tooling Processing for protection of o-ring and seal grooves Closing Small Pitted Areas Protection for Welding Tensile Stresses back to benefits MetaLL*ifeŇ protects die casting tools from initial or subsequent thermal stress heat checking by replacing detrimental residual tensile stresses with an encapsulating surface protective layer of compressive stress. See X-ray diffraction Lambda Curves. This compression is also present even in cases where the cracks are too large to actually be closed. By having a compressive force on each end of these cracks, further propagation of the larger cracks is prevented. Cracks cannot propagate into or through this layer of compressive stress unless the increased effective yield fatigue strength of the steel is exceeded which MetaLL ifeŇ increases by 30-40%. If Metallife is performed when the tool is NEWer, a cold work plastic flow occurs that closes minor smaller heat checks under compression. MetaLL*ifeŇ stress protection can be applied to NEW tools to retard the start of heat checking or to USED tooling to safeguard against subsequent heat check propagation. It is possible to close smaller existing cracks in used tooling. Larger cracks that cannot be closed are still encapsulated at each end of the crack in a compressive stress layer. As most metallurgists know, a crack will not propagate into or through a layer "); array_files[82]=new Array(0,1,"http://www.badgermetal.com/ml-dc/signif-dc.htm","2009-07-17","29K","Resistance to thermal fatigue cracking, reduce cavitation effect in die casting dies, Metallife to lower die temperature ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","How Metallife will significantly extend tool life by reducing fatigue of die casting dies "," Resistance to thermal fatigue cracking, reduce cavitation effect in die casting dies, Metallife to lower die temperature Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Significantly Extends Die Life back to benefits In 3 ways Resistance to thermal fatigue Reduces Cavitation Effect resulting in die steel breakout Lowers temperature of the dies surface Compression - The depth and value of the compressive stress layer induced during the MetaLL ifeŇ 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*ifeŇ takes the smooth surface finish at critical locations of a dies 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 "); array_files[83]=new Array(0,1,"http://www.badgermetal.com/ml-dc/gross-cracking.htm","2009-07-17","24K","Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","Gross cracking is a catastrophic failure of a die casting tool with examples "," Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com NADCA Die Materials Studies Gross Cracking - Cause & Effect Study Download this Powerpoint presentation Gross Cracking is a catastrophic failure of a tool where the cracking is so severe and large that the integrity of the tool is challenged. Often this type of failure is unrepairable and requires replacement of the tool. Quite often it initiates at the water line or some area on the die that requires toughness. Photos of Gross Cracking Examples Incoming steel toughness measured by charpy impact testing and verification is sometimes missed by the end user, thinking that a premium grade H-13 steel or other hot work steel is assured to have the required toughness. NADCAs spec 207-2006, however, calls out a minimum 10 ft lbs of charpy v notch strength. Heat treat can improve or degrade the required properties of the steel and is a very important ingredient in getting proper micro structure, banding, etc... NADCA Heat treat spec 207-2006 - order here from NADCA. In the NADCA spec, charts are shown that grade the currently most used hot work types and show guidelines on proper heat treat procedures. To preview some of these charts click on the below button. Pdf of 207-2006 charts onlyTo summarize findings of NADCAs Die Material Committee (DMC), we have created a short 9 slide powerpoint presentation which can be viewed directly from our web site or downloaded for off line viewing. This slide show will give a quick read on how to protect yourself from Gross Crack failures. To navigate this sli "); array_files[84]=new Array(0,1,"http://www.badgermetal.com/ml-dc/decreses-solder-dc.htm","2009-07-17","37K","Metallife and Thermallife extend die casting die life, stopping soldering and improving performance of die casting dies and other molds. ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","How soldering in die casting dies starts and how to prevent soldering in die casting dies "," Metallife and Thermallife extend die casting die life, stopping soldering and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com back to benefits Decreases Soldering of Die Casting Dies Ultrasonics for the future Remove the solder Die Casting Dies Recent studies from 2006 and continuing into 2008 by various labs and organizations have found that one of the many causes of soldering is due to the impingement of aluminum to the die steel which effectively weakens the steel. This along with temperature, wettability, and metal velocity are other contributing factors. To make a bad situation even worse, aluminum (Al) and iron (Fe) have a natural chemical affinity to one another because of their make up and electron imbalance. When contacting each other, they want to form intermetallic compounds. Stage Description Cause I Erosion of grain boundaries Weak regions - cavitation II Pitting of die surface Loose grain - cavitation III Formation of iron-aluminum compounds Chemical - electron imbalance IV Formation of pyramid shapes Rapid diffusion of iron V Adherence of Aluminum Cracks in surface at pyramids VI Erosion pits Cavitation loss of yield strength courtesy - Worcester Polytechnic Institute - Diran Apelian Loss of the tools protective surface or lubrication barrier between the die and cast molten metal allows the creation of intermetallic compounds that cause a chemical adhesion or soldering of the metal to the dies surface. This is most prevalent when an aluminum component is present in the cast metal alloy which can also include some zinc alloys. The aluminum alloy and tool steel iron content have "); array_files[85]=new Array(0,1,"http://www.badgermetal.com/ml-dc/diptest-dc.htm","2009-07-17","38K","Case Western study of the effects of compressive stress to improve die life in die casting molds and reduce thermal fatigque cracking ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","Case Western dip tank test to show how Metallife reduces the tendency for cracking in die casting dies "," Case Western study of the effects of compressive stress to improve die life in die casting molds and reduce thermal fatigque cracking Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com To further confirm the benefits that were being reported in numerous field tests, we requested Case Western Reserve University, under the auspices of Professor John Wallace, to conduct their traditional Dip Tank Test. This test evaluates the performance of the MetaLL ifeŇ process in relation to edge cracking of H13 materials. A specimen is prepared from H13 material that measures 2 x 2 x 7. The specimen is then austenitized at 1900°F for one and one-half hours and then oil quenched. This is followed by tempering cycles at about 1100°F for one hour and an oil quench to give the final hardness value of 46 HRC. The model is then surface ground and polished so each corner had a .010 radius with all corners square to within +/- .003 of an inch. The corner radius is formed on each corner by manually stoning with successive grits of 240, 320, 400, and 600 grit papers along the length of the corners of the block. The papers are clamped in a V-notch block to achieve the required radius and checked with a radius gauge at each corner. Each dip tank test cycle consists of a 12 second immersion in 380 aluminum alloy, followed by 24 seconds of air cooling out of the molten metal solution. The specimen is internally cooled at a rate of one gallon per minute. The aluminum alloy is maintained in a gas-fired crucible furnace at an average temperature of 1300°F which is moni "); array_files[86]=new Array(0,1,"http://www.badgermetal.com/ml-dc/top-cracks-ej.htm","2009-07-17","25K","Metallife and Thermallife preventative maintenance to extend die casting die life and improving performance of die casting dies and other molds. ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","Proactive preventative maintenance to extend the life of die casting dies by reapplication of Metallife "," Metallife and Thermallife preventative maintenance to extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Dramatic Field Test Results Comparing treated and untreated surfaces on the same tool. Return to Stops Heat Checking Page The below photos show the benefit of the re-application of MetaLL ifeŇ Casting from die - no reapplication of MetaLL ifeŇ. Condition at 72,000 shots (not cavitation breakout) (processed only once well into life of tool) Casting from die processed with MetaLL ifeŇ (when new and every 30K). Condition at 112,000 shots (still running parts at 160,000 shots) Return to Stops Heat Checking Page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[87]=new Array(0,1,"http://www.badgermetal.com/ml-dc/enhance-dc.htm","2009-07-17","25K","Metallife and Thermallife extends die casting die life and enhances fill characteristics of die casting dies and other molds. ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","How Metallife enhances fill characteristics in magnesium and aluminum die casting dies "," Metallife and Thermallife extends die casting die life and enhances fill characteristics of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Enhances Fill Characteristics Magnesium & Aluminum die casting dies back to benefits It is common knowledge in the die casting industry that topography improves the flow of metal. Die casters, in the past, achieved this by stepping the gate or cross hatching it. A tool after MetaLL ifeŇ processing has a slightly compressive topograpy. This surface can vary depending on the T process applied. Because of this compressive topography, molten metal coming into the die becomes more turbulent which forces a roll over action on the active face of the tool. This permits better filling during the die casting cycle. The wave action of the topography also breaks up the trapped gases in the molten metal into smaller bubbles. This produces castings with more homogeneous porosity distribution of the smaller trapped gases instead of the large random areas and reduces or eliminates cavitation effect that leads to metal break out. For this reason the runner and gate of inserts are automatically included areas. Magnesium die castings are more sensitive to the flow effect because most castings of this material have much thinner walls combined with the fact that molten magnesium is poured at a higher temperature (1320-1350 degrees F) than aluminum. This poses a problem with the flow due to the rapid heat transfer of magnesium alloys. When a magnesium die is MetaLLifeŇ processed, however, the molten metal flows more evenly over the created peaks preventing solidification lamination improving casting "); array_files[88]=new Array(0,1,"http://www.badgermetal.com/ml-dc/applies-dc.htm","2009-07-17","26K","Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","Metallife applications and Thermallife applications for applying to hot and cold work steels to increase die life "," Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Applies to Hot & Cold Work Steels back to benefits MetaLL ifeŇ is not a coating or plating but a molecular stress change to the surface of the steel. Penetration depth is .010 to .018 of an inch subsurface. Since it is performed at room ambient conditions with no heat involved, the initial heat treat specifications cannot be compromised or changed. There is also no danger of distortion, size or tolerance changes. Applications include all type of hot & cold work steels including: Hot Work (H-13 , P-20, and Maraging) and Cold Work (D2, A2, O2 and others) steels. The process may be applied as often as required or desired with no build up on the tool since only the base metal surface is affected with nothing being deposited to the dies surface. The below macro photo shows a treated and untreated specimen of H-13 steel. Note how well the surface inclusions and polish marks have been removed by the MetaLL ifeŇ process. The evident topography is inversely proportional to the hardness of the material. H-13 will show more topography (which is desired in die casting to reduce cavitation effect) because of its relative softness (44-48Rc) as compared to Cold Work steels hardness of 58-62Rc. For Cold Work steels the topography is not readily evident to the naked eye but can be seen if the surface is magnified (10x lupe). MetaLL ifeŇ area shows uniform topography and no inclusions. Unprocessed half with inclusions and polish marks over the entire surface back to benefits Page was last modified Sunday, "); array_files[89]=new Array(0,1,"http://www.badgermetal.com/ml-dc/mag-photos.htm","2009-07-17","23K","Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","Applying Metallife to die casting dies for magnesium to improve flow in die casting dies "," Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Photos of some of the many magnesium die casting dies that we have processed Below photos are all magnesium tools Enhances Metal Flow Extends die life back to benefits click on photo for larger image (may take a few seconds to download) back to benefits Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[90]=new Array(0,1,"http://www.badgermetal.com/ml-dc/gross-crack-photos.htm","2009-07-17","28K","Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","Examples of gross cracking in die casting dies "," Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Example of typical Gross Cracking Courtesy Bodycote Labs This view shows a crack that runs down one of the side faces and into a longitudinal groove on the side. Red arrows mark the ends of the crack. This is a closer view of the crack as seen in a top-down view. The two red arrows indicate the ends of the crack. This view shows the crack that runs down the other side face and into longitudinal groove. Red arrows mark the ends of the crack. This is a view of a water line crack. The green circle indicates the fracture surface of one of the cracks that is radiating from the water cooling line that was exposed. This is a close view of cracks radiating from a cooling line. Red arrows indicate cracks emanating from the cooling line at the 3:00 o’clock and 9:00 o’clock positions. The crack at the 9:00 o’clock position is about 5/16” long, while the crack at the 3:00 o’clock position is approximately 1/2” long. This is a 50x magnification view of the cross-section of a water line fracture origin. The fracture surface is just to the right. Note that there are several other cracks seen in this cross-section through the valley. The multiplicity of cracks offers evidence that the insert experienced high service stresses. Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohi "); array_files[91]=new Array(0,1,"http://www.badgermetal.com/ml-dc/increase-dc.htm","2009-07-17","24K","Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds by creating micro pockets to trap lubricant. ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","Metallife increases lubricity by lube retention "," Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds by creating micro pockets to trap lubricant. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Increases Lubricity back to benefits The topography of MetaLL ifeŇ creates micro pockets for trapping and holding lubricant on the surface of the tool. Since lubricant is more efficiently retained on the die, customers report reduced spray times and/or the need to apply less lubricant. The process also adds a lubricity factor to the dies surface to improve metal flow. This along with the increased surface area caused by the non-linear surface lowers the thermal gradient (more surface area for cooling) while providing a more effective foundation for lubricant retention and casting release. Some die casters report being able to lower die pressures after a MetaLL ifeŇ surface has been applied. A February 2007 NADCA Die Materials Committee report from Case Western University, documents the negative effect that aggressive spraying has with regards to premature cracking. As the spray time is increased, the cycle swing and temperatures of both the surface and sub-surface (0.08) of die tool steel increases. These cycle temperatures can lead to premature heat checking. This testing by Case Western confirms that longer lubricant spray time causes larger thermal cycles which thereby shortens tool life. back to benefits Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express writte "); array_files[92]=new Array(0,1,"http://www.badgermetal.com/ml-dc/weld-stress-correction.htm","2009-07-17","23K","Metallife and Thermallife extend die casting die life and improving performance of welded die casting dies and other molds. ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Why it is important to remove stresses in die casting dies after welding die casting dies "," Metallife and Thermallife extend die casting die life and improving performance of welded die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Welding Stress What is it? How to Correct it. Return to Stops Heat Checking Page Residual tensile stress from welding is created because the weld consumable is applied in its molten state. This is its hottest, most expanded state. It then bonds to the base material, which is much cooler. The weld cools rapidly and attempts to shrink during the cooling. Because it has already bonded to the cooler and stronger base material, the weld is unable to shrink. The net result is a weld that is, essentially, stretched by the base material causing a tensile stress condition. The heat affected zone is usually most affected by the residual stress and hence where failure will usually occur. Inconsistency in the weld filler material, metal chemistry, weld geometry, porosity, etc..., act as stress risers for the residual and applied tensile stress to initiate die fatigue failure. As shown below, MetaLL ifeŇ is extremely beneficial in reversing the residual stress from welding that tends to cause failure. These stresses in the die cast tools heat affected zone are converted to a beneficial compressive state. The below graph demonstrates a number of interesting changes in residual stress from welding, thermal stress relieving and from MetaLL ifeŇ. Tensile stresses generated from welding are additive with applied load stresses. This is why these combined stresses accelerate failure at welded locations. Heat stress tempering to reduce the tensile to zero (approximate) then following with MetaLL ifeŇ, "); array_files[93]=new Array(0,1,"http://www.badgermetal.com/ml-dc/residual-stress-baseline.htm","2009-07-17","24K","Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","Residual stresses in die casting dies build at a quick rate. Presentation showing baseline study of residual stress in die casting dies "," Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com 2003 NADCA Task Force Residual Baseline Study Download Excel Spreadsheet with data Download this Powerpoint presentation In March of 2003, a baseline study was concludes that showed how fast stress builds up in die casting H-13 material. Case Westerns used their for this their repeatable and accepted dip tank test. The results of this test, although still ongoing, showed that after only a few cycles that tensile stresses enough to crack material are present.These occurred after only 10 cycles. It is interesting to note that the breakout phenomonon did not occur in this or any other tessting of this nature where pressure and velocities were not involved. Fluid dynamics were not part of this study. More on cavitation effect can be found at this link CAVITATION.The Excel spreadsheet and Power Point slides show how the polished only compressive stress points in green changed to tensile stress points in red. From the results three hypothesis were drawn. Cycling the die generates increased tensile stresses that are relieved by cracking. Flexing the die surface through compressive and tensile conditions lead to die failure. Decarburization may be softening the surface reducing the yield strength. This data confirms the importance of compressive stress to protect against fatigue failure. 15 slides of success Please wait until slides shows load into memory Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. "); array_files[94]=new Array(0,1,"http://www.badgermetal.com/ml-dc/edm-dc.htm","2009-07-17","30K","Metallife and Thermallife extend die casting die life and improving performance charpy impact strength of die casting dies and other molds. ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","Case Western study on the detrimental effect of EDM finishes to die casting dies "," Metallife and Thermallife extend die casting die life and improving performance charpy impact strength of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Badger Metal Tech offers a variety of topographies that range from a light (T10) to a maximum (T71 ) finish. For this test two EDM methods were used that involved, a regular intensity EDM (R.l.M.) and high intensity EDM (H.l.M.) process that was small enough to ensure penetration of the small .010 radius of the Charpy block. Five H-13 coupon samples of each intensity were tested. Two E2 sets (5 ea) were prepared. One set was tempered (T) and polished (P) prior to MetaLL ife. The other set was only polished (P) prior to the treatment. Another set of E5 (5 ea) specimens was prepared without any tempering or polishing prior to processing. The action of MetaLL ife involves proprietary spherical media that, under rigid controls, bombards the surface of the tool steel. Each piece of media striking the surface acts as a tiny hammer, imparting small indentations on the surface. The formation of these indentations yields the surface fibers of the material in tension. Below the surface, the fibers try to restore the surface to its original shape and thereby create a cold worked material highly stressed in compression. The rigid controls allow the overlapping dimples to develop an even layer of residual compressive stress. Tension is usually the stress that produces cracking in steel. The opposing compressive stress layer, which is in the range of 130-140% of the materials effective yield strength, prevents cracks from propagating. The Charpy V-notch specimen for all surface "); array_files[95]=new Array(0,1,"http://www.badgermetal.com/ml-dc/cavitation-effect.htm","2009-07-17","58K","Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","A full study of the effects of cavitation in die casting dies including videos and slide presentations "," Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com fixing other modes of die casting (diecasting) failures Cavitation Effect on Die Cast Tooling and its Relationship to: Breakout & Lamination, Laminar Fill, & Blistering MetaLL* ifeŇ Benefits Cavitation videos - strong destructive forces to die casting dies. 3min clip - Windows Media file Requires Media Player University of Minnesota Lab Studies on cavitation - courtesy Dr. Roger Arndt This video shows the generation and effect of vortex and sheet cavitation. 3min clip - Windows Media file Requires Media Player The Scablands - Geologic cavitation Water and aluminum has similar flow characteristics The destroyed rock is your die material. Read below for how to correct it. Click on photo or movie reel to view video Click on photo or movie reel to view this video graphics may take a few moments to load - Please wait The premature failure phenomenon of breakout occurs in other industries besides die casting. Often it is experienced in pumps and other products such as boat propellers as well as other hydraulically operated machinery. The boat propeller will literally be eaten away over time without being subjected to any type of outside abrasive or destructive environment other than water. Why is this? Prop cavitation effect Cavitation damage In hydraulic pumps, it occurs, not on the high pressure side but rather on the low pressure side and was misunderstood for years. Unfortun "); array_files[96]=new Array(0,1,"http://www.badgermetal.com/ml-dc/solder-test/solder-fnc-graph-wt.htm","2009-07-17","20K","What causes soldering in die casting dies and how to correct it ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Summary graphs showing a thick vs thin Thermallife to prevent soldering in die casting dies "," What causes soldering in die casting dies and how to correct it Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Return to Graph Summary Page Return to Graph Summary Page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[97]=new Array(0,1,"http://www.badgermetal.com/ml-dc/solder-test/solder-solutions.htm","2009-07-17","24K","What causes soldering in die casting dies and how to prevent soldering ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Keeping a barrier between the steel H-13 and the aluminum prevents soldering of die casting dies. "," What causes soldering in die casting dies and how to prevent soldering Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Return to Solder Page Spraying the surface of the die will help create a barrier to prevent soldering. Spraying also contributes to thermal shock and an increase in tensile stress build up that eventually leads to heat checking. It is important to maintain good die lube retention by spraying. The spray wetting of the surface can, as long as present, help to maintain a barrier between the aluminum and iron It is best to apply a diffusion process to create a compound layer at the surface that generates a non-contributing barrier that will not allow aluminum to interact with the iron. This will protect areas that receive inadequate spray wetting. PVD coatings are beneficial, however, will fail if the substrate material stress cracks due to thermal cycling of the die casting die. Photo showing absence of bond After intermetallic bond In some cases intermetallic phases occur even in the absence of a bond Return to Solder Page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[98]=new Array(0,1,"http://www.badgermetal.com/ml-dc/dh-dies-large-view.htm","2009-07-17","24K","Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","Before and after photos of crack closure repair in die casting dies "," Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Compressive Stress results Return to Stops Heat Checking Page Return to Advanced Info Page The below photos show compressive impaction effect ofMetaLL ifeŇ Unretouched photos of before and after results of compressive MetaLL ifeŇ. process. Return to Stops Heat Checking Page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[99]=new Array(0,1,"http://www.badgermetal.com/ml-dc/elim-dc.htm","2009-07-17","24K","Metallife - Eliminates EDM Stresses in die casting dies that have the white layer present or removed ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","Leaving the white cast layer on EDM produced die casting dies will cause premature failure "," Metallife - Eliminates EDM Stresses in die casting dies that have the white layer present or removed Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Eliminates EDM Stresses back to benefits Electrical Discharge Machining while providing a relatively inexpensive means for producing die casting die inserts, unfortunately, at the same time, sets up some very high and detrimental EDM surfaces stresses that if not properly tended to will actually accelerate thermal stress cracking. Since metal is removed by a series of electrical spark discharges, the steel in the contact area melts or vaporizes then solidifies on the surface of the cavity. Each spark erodes a tiny bit of metal, leaving a small crater in the surface of the tool. This leaves the surface in a high residual stress condition which can lead to early heat checking and possible gross cracking. The top most or recast layer is a brittle, non-etch white layer containing cracks. This is the material that has melted and rapidly solidified and is not flushed away by the die electric fluid. This layer is densely infiltrated with carbon and has a distinct separate structure to that of the parent metal. Below this layer is the heat affected zone that has been structurally altered by the heat produced during EDM which reaches the austenizing temperature of the steel. This zone may contain re-hardened or hard, brittle untempered martensite which is formed during the rapid cooling from this temperature. This can be expected to increase crack susceptibility since such a microstructure stores "); array_files[100]=new Array(0,1,"http://www.badgermetal.com/ml-dc/verifies-dc.htm","2009-07-17","24K","How to verify your die casting die hardness after heat treatment ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","Metallife will verify that your heat treat hardness is correct "," How to verify your die casting die hardness after heat treatment Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Verifies Surface Hardness / Integrity back to benefits Dies that are inherited from another die caster are sometimes very old. Sometimes there is no history to show what prior maintenance was done to the tool. MetaLL ifeŇ verifies the relative surface hardness of dies and then gives visual evidence after processing that verifies where and if the dies has been nitrided, welded, coated, or improperly quenched when heat treat. In addition each insert over 50lbs. is surface hardness checked prior stress tempering and before processing, using an EquoTip velocity hardness tester to ensure consistency. If you have a porous or bad weld, it will usually show up after we process your tooling. The EquoTip is unique in that it leaves no dimpling on the die surface so measurements can be taken in the most meaningful place - the casting wet metal areas. It is not as accurate as a dimple tester, but it confirms relative hardness by velocity bounce back readings and it is totally portable. back to benefits Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole pr "); array_files[101]=new Array(0,1,"http://www.badgermetal.com/ml-dc/successfully-dc.htm","2009-07-17","34K","Cavitation effect that causes breakout in die casting dies and how to prevent erosion and washout in die casting dies ","heat checking,fatigue cracking,breakout from cavitation,Metallife,Thermallife,Metalife,Thermalife,die life, tool life,porosity,lamination,laminar fill,pitting,coatings,die surface treatments,die casting,die cast die welding,thermal fatigue, premature tool failure,edm effect,gate erosion,washout,peening,shot peening,fnc,ferritic nitrocarburizing,nitrocarburizing, nitro-carburizing,dynablue,dyna-blue,dyna blue,case hardening,nitriding,die substrate,die soldering,reduce scrap,scrap rate reduction, texturing,die surface texturing,casting texturing,compressive stress,stress relieving,stress temper,lubricity,die lube retention, die spray,improved flow,reduce flow lines,gate and runner systems,gate texturing,rocklinzing,balzers,phygen,colorado school of mines, philo,salt bath,melonite,Metal life,Metal life process,metallife process,die casting surface treatments,die surface treatment, die surface engineering,metal life surface treatment,die lube, die lubricant,die casting lubricant,die lubricity,lubricity, shot peening,metallife peening,die shot peening,peening,laser peening,precision peening,precision peening process, precision shot peening,precision shot peening process,residual stress,controlled residual stress,compressive stress texturing, residual compressive stress,compressive stress,surface compression,weld peening,weld shot peening,cycle failure,surface coating, die casting coating,coating process,die surface coating,mechanical coating,mechanical coating process, ","Historical evidence showing the true causes for erosion and breakout in die casting dies "," Cavitation effect that causes breakout in die casting dies and how to prevent erosion and washout in die casting dies Metallife and Thermallife extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Substantially Eliminates Gate Cavitation Reducing Breakout, and Erosion (Washout) back to benefits Hover mouse and click on the above button to discover the real cause for your pitting and breakout Click on the above to complete the definition and catestropic effect of cavitation to die steel It is considered a prudent practice to degas molten aluminum. The reason and principal behind this is to reduce the retained gases which in addition to adding casting porosity also lead to premature erosion and/or pitting (breakout) in the gate area. This is a common phenomenon known in many industries that deal with liquids, especially pumps. It also occurs too frequently during die casting operations. Many dies that pass through our facility usually have some type of breakout in the gate or other high velocity fill area. MetaLL*ifeŇ can sometimes, through its plastic flow characteristics, close up the smaller pits, however, we cannot put back large pieces of missing metal. Molten metal inherently has some remaining gas bubbles left in solution even after degassing. Because of remaining gases in molten aluminum, this liquid can be compressed and expanded. The trapped gases entering the die via the runner collapse and hammer the dies surface millions of times with every shot. This hammering effect eventually leads to the die steel being broken down or washed away. This is the similar "); array_files[102]=new Array(0,1,"http://www.badgermetal.com/ml-dc/solder-test/solder-thick-vs-thin.htm","2009-07-17","23K","What causes soldering in die casting dies and thicker diffusions ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Precautions when using ferritic nitrocarburizing and having a thick vs thin diffusion layer "," What causes soldering in die casting dies and thicker diffusions Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Use these icons on the top of every page of our web site.to quickly navigate or return home Return to Summary Page Thick diffusion attained by increasing recipe for temp, time, gases. Thin diffusion attained by decreasing recipe for temp, time, gases. Macro Photo of thick layer showing with micro-hardness points graphed below Macro Photo of thin layer showing with micro-hardness points graphed below Thicker diffusions provides good washout and erosion but are prone to developing thermal cracking which can easily propagate into the base metal. Thin diffusion zones provide good soldering protection and excellent thermal cracking resistance since they are more flexible. Return to Summary Page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[103]=new Array(0,1,"http://www.badgermetal.com/ml-dc/solder-test/solder-fnc-graphs.htm","2009-07-17","23K","What causes soldering in die casting dies and how to correct it ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Curves and Graphs showing soldering in die casting dies "," What causes soldering in die casting dies and how to correct it Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Return to Solder Page % of Pin Surface Soldered as a function of shots Click on graph to view a larger image Pin weight loss (erosion) in grams as a function of shots Click on graph to view a larger image Weight of solder on pins for control H-13 and processes Click on graph to view a larger image Click on any of the above curves or graphs to view a larger image Return to Solder Page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[104]=new Array(0,1,"http://www.badgermetal.com/ml-dc/solder-test/solder-summary.htm","2009-07-17","24K","What causes soldering in die casting dies and using ferritic nitrocarburized coatings ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Summary page of soldering in die casting dies, causes, solutions, precautions "," What causes soldering in die casting dies and using ferritic nitrocarburized coatings Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Return to Solder Page Macro Photo of thick coating showing cracking of the compound layer after cyclical thermal fatigue of base H13 material. Thick and Thin Ferritic nitrocarburizing improves the resistance of H13 pins to soldering (sticking of aluminum) but does not totally prevent it. Ferrritic nitrocarburizing improves significantly the resistance of H13 pins to washout (loss of base metal) of material. Thick ferritic nitrocarburized diffusion layers provide better resistance to washout, however, tend to crack, chip or give the appearance of peeling or flaking. This is most likely seen in thicker rather than thinner diffusion compound layers. Based on these tests and field observations, thick nitrocarburized coatings are not advisable for solder intensive applications or thermal fatigue protection. Thin ferritic nitrocarburized coatings are more mallable to tolerate thermal fatigue situations than thicker diffusion layers. Return to Solder Page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[105]=new Array(0,1,"http://www.badgermetal.com/ml-dc/solder-test/solder-cause.htm","2009-07-17","23K","What causes soldering in die casting dies and how to correct it ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Loss of lubricant or barrier initiates soldering in die casting dies "," What causes soldering in die casting dies and how to correct it Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Return to Solder Page Aluminum 390 Alloy has a high content of Silicon (Si). Various covalent bonds of the Al, Fe, and Si are therefore formed when the barrier is lost. Hot spots on the dies surface can eventually cause a loss of lubricant by burn off. Since aluminum (Al) and iron (Fe) have a natural affinity for each other, the loss of lubricant, temperature of the metal and impingement of the aluminum weaken the surface which leads to chemical changes to the dies surface. Over the time, temperature, and velocity combinations, the aluminum impinges on the surface to interact with the iron to form an intermetallic covalent bond. Chemical corrosion Click here for more on the solder mechanism Return to Solder Page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[106]=new Array(0,1,"http://www.badgermetal.com/ml-dc/solder-test/solder-labtest.htm","2009-07-17","30K","What causes soldering in die casting dies and how to correct it again removed ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Testing at Case Western University to prove the effectiveness of reducing soldering in die casting dies. "," What causes soldering in die casting dies and how to correct it again removed Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Return to Solder Page Test was performed under a controlled environment using a die casting machine with the test pins specially constructed to experience an extremely shortened life when placed directly in the line of metal flow. 300in/sec. with each shot averaging about 6 lbs. The arrangement of the two pins allows for a comparison of a control H-13 pin to other materials, surface treatments, or diffusion processes. Test procedures were developed to give an accelerated report on actual soldering and washout conditions as might be experienced during production die casting. Click on diagram to view a larger image and other data H13 Control Pin TherMaLLifeŇ Pin Core prior to test Process Core After 30 shots (equivalent 10,000 shots) After 30 shots (equivalent 10,000 shots) Solder removed by dissolving with NaOH Solder removed by dissolving with NaOH After 50 shots at end of test After 185 shots at end of test Solder again removed with NaOH - note erosion and loss of H13. Solder again removed with NaOH - very little erosion of the H13 and loss of h13. Aluminum impinged surface of H13 control pin (50 shots) before solder removal as shown on the right side of this photo. Aluminum impinged surface of processed core pin (50 shots) before solder was removed. Return to Solder Page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of B "); array_files[107]=new Array(0,1,"http://www.badgermetal.com/ml-dc/solder-test/solder-fnc-graph-barwt.htm","2009-07-17","20K","What causes soldering in die casting dies and how to correct it ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Creating a barrier with Thermaillife reduces soldering in die casting dies "," What causes soldering in die casting dies and how to correct it Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Return to Graph Summary Page Return to Graph Summary Page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[108]=new Array(0,1,"http://www.badgermetal.com/ml-dc/solder-test/solder-fnc-graph-percentage.htm","2009-07-17","20K","What causes soldering in die casting dies and how to correct it ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Various recipes for applying Thermallife to stop die casting die failure "," What causes soldering in die casting dies and how to correct it Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Return to Graph Summary Page Return to Graph Summary Page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[109]=new Array(0,1,"http://www.badgermetal.com/ml-dc/solder-test/solder-labtest-setup.htm","2009-07-17","21K","What causes soldering in die casting dies and how to correct it ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Testing set up at Case Western to run soldering in die casting die test "," What causes soldering in die casting dies and how to correct it Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Return to lab test page Each Shot amounts to about 6 lbs. of molten aluminum UBE VSC 315 Ton Squeeze Casting Machine at CWRU Return to lab test page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[110]=new Array(0,1,"http://www.badgermetal.com/ml-dc/solder-test/solder-substrateprep.htm","2009-07-17","25K","What causes soldering in die casting dies and how to correct it with coatings ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Why coatings PVD coatings are not always effective in reducing soldering in die casting dies "," What causes soldering in die casting dies and how to correct it with coatings Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Return to Solder Page Columnar coating grain size 40-50 nanometers x50,000 PVD coatings alone without substrate support are not the solution since most times they are laid down in a crystalline columnar matrix, which can be prone to cracking failure. Openings between the crystal structure of the coating provide direct pathways to the steel below unless a matrix of coatings is applied. Unfortunately this is an expensive way to solve the substrate problem and difficult to find commercial availability. As die tensile stresses build, these openings expand providing direct unprotected pathways to the substrate material. If the substrate is not protected, cracks develop causing the coating to also fail. Click here for more on the solder mechanism. Our substrate of TherMaLLifeŇ creates, in addition to a hard diffused layer, a compound ceramic layer that prevents the aluminum and iron from interacting. This phenomenon was studied by Case Western University. Click the right arrow above for the results of this test. Return to Solder Page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[111]=new Array(0,1,"http://www.badgermetal.com/ml-dc/solder-test/solder.htm","2009-07-17","24K","What causes soldering in die casting dies and how to correct it ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Soldering in die casting dies, what causes soldering in die casting, how to prevent soldering and testing at Case Western to confirm solutions. "," What causes soldering in die casting dies and how to correct it Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com You may navigate using the blue arrows or click on each lettered item. A. Aluminum Solder Causes B. Substrate Preparation C. Lab Test 2002 Case Western University D. Graphs & Curves E. Anti-Solder Solutions F. Summary & Conclusions Intermetallic bonding of aluminum Macro photo of bonding layers Photo showing absence of bond After intermetallic bond In some cases intermetallic phases occur even in the absence of a bond Return to Home Page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[112]=new Array(0,1,"http://www.badgermetal.com/newsletters/1995-01.htm","2009-07-17","24K","Newsletter - 1995-01 Gambling Algebraically ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 1995-01 Gambling Algebraically Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com January 1995 Bulletin Gambling Algebraically Print this Newsletter Even though the magnitude of induced compressive stress with MetaLL ifeŇ is well managed, the resulting total effective value is determined algebraically by the starting tensile stress (+KSI) existing in the die at the time of processing. During normal use, these levels of tensile stress can become quite high. Heat stress tempering is recommended after a prescribed number of shots since it removes most to all of these built up stresses returning the steel to a normalized state. When starting from a normalized zero condition, the effective optimized T-41 compressive stress depth for 44Rc H-13 material is approximately -40KSI. If processing is performed to tooling that has existing tensile stress parameters, this value is reduced to the Algebraic Sum of the existing tensile (+KSI) and compressive stress (-KSI) levels. The resulting final value may end up being significantly less than the expected -40KSI value. To illustrate this let us assume that a tool has an average +20KSI value of tensile stress at the time of processing. The resulting net value of compressive stress then becomes -20KSI or ( [+20KSI] + [-40KSI ]) = -20KSI. In this example, the magnitude of protection against subsequent stress cracking has been reduced by 50% simply because of the existing tensile stress in the tool. The difference between a normalized tool and this example is shown in the below graph: A die caster is, therefore, taking the Algebraic Gamble regarding the final induced compressive stress level when processing "); array_files[113]=new Array(0,1,"http://www.badgermetal.com/newsletters/1997-03.htm","2009-07-17","16K","Newsletter - 1997-03 Modes and Causes of Die Failure - Part 3 ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 1997-03 Modes and Causes of Die Failure - Part 3 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Print this Newsletter Badger Metal Tech, Inc. N60 W15088 Bobolink Ave. Menomonee Falls, WI 53051 262-252-3804 FAX 262-252-3956 TOLL FREE in the United States and Canada - 800-366-1973 Volume 4 Issue 3 Modes & Causes of Die Failure Part 3 March 1997 Our examination of the modes and causes of die failure due to cracking have shown two types of failure -heat checking and gross cracking. The Figure 1 schematic shows a cross section of a die and the stress physics associated with thermal or heat check cracking. Molten metal contacts the die and causes the surface temperature to increase more than the interior of the die. The die face (Diagram1) starts to expand, however, the cooler underlying layer resists. This creates a temporary compressive stress layer. When the casting is removed, the die surface starts to cool (Diagram 2) and as it does, the surface shrinks. The surface cools more quickly, however, than the interior of the die which places the die’s sub-surface in residual tension stress which is exacerbated (Diagram 3) by the application of die lubricant. The curved dotted line in each drawing shows the relative difference in temperature for the interior of the die. Continued cycling of the die, as shown in Figure 2, eventually reduces the yield strength of the tool which causes subsequent higher residual tensile stresses to develop and along with this, the initiation of the all too common thermal stress cracks. This type of cracking is more prevalent in aluminum and brass die casting tools due to the high contact temperature and resulting thermal shock of the molten metal and alloys used. Premature escalating heat checking is averted by good steel selection, proper he "); array_files[114]=new Array(0,1,"http://www.badgermetal.com/newsletters/1997-11.htm","2009-07-17","9K","Newsletter - 1997-11 Solving Soldering Problems ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 1997-11 Solving Soldering Problems Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Print this Newsletter This is an archived page and cannot be changed "); array_files[115]=new Array(0,1,"http://www.badgermetal.com/newsletters/2001-03.htm","2009-07-17","20K","Newsletter - 2001-03 Recession Warning ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 2001-03 Recession Warning Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Print this Newsletter This page was last updated July 07, 2009 Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[116]=new Array(0,1,"http://www.badgermetal.com/newsletters/1996-01.htm","2009-07-17","31K","Newsletter - 1996-01 Recapping Metallife Benefits ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 1996-01 Recapping Metallife Benefits Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com January 1996 Bulletin Recapping Benefits Print this Newsletter MetaLL ifeŇ offers other significant benefits to proactive die casters besides the compressive stress layer that protects against initial metal fatigue and crack propagation. These benefits are just as REAL and show up on the bottom line as cost justified savings. Our resulting topography should not be compared with processes that cause only a cosmetic change to the surface. These types of topography do not protect the tool from premature or subsequent heat checking. Beneath the readily distinct MetaLL ifeŇ topography, however, is a proactive layer of residual compressive stress. This layer raises the effective yield strength of the die steel. Metallurgical existing cracks are prohibited from propagating into or through the layer. Smaller cracks that may already exist are closed and put into compression to retard future site cracking. Texturing by acid or photo etching does not generate this compressive layer and can only create a cosmetic change to the surface. The difference is like comparing apples to oranges. Here is a recap of some of the other proactive benefits that MetaLL ifeŇ provides. Lubricity The generated micro pockets trap lubricant which assist in casting release and reduce soldering. Flow Enhancement Molten metal distribution in the die is enhanced to provide more effective fill characteristics. This phenomenon is optimized and most apparent when BOTH sides of the tool are processed. Blends Porosity The MetaLL ifeŇ surface produces turbulation of the molten metal coming into "); array_files[117]=new Array(0,1,"http://www.badgermetal.com/newsletters/1998-06.htm","2009-07-17","9K","Newsletter - Residual Stress Part 4 ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - Residual Stress Part 4 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Print this Newsletter This is an archived page and cannot be changed "); array_files[118]=new Array(0,1,"http://www.badgermetal.com/newsletters/1995-04.htm","2009-07-17","27K","Newsletter - 1995-04 Flow Chart to Maximize Tool Life ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 1995-04 Flow Chart to Maximize Tool Life Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com April 1995 Bulletin (modified in 2002 to include TherMaLLifeŇ) Flow Chart To Maximize Tool Life Print this Newsletter Everyday we are asked - What steps should I take to prepare the tool so that tool life and performance is maximized? In response to this we have prepared a flow chart that is beneficial to first time customers who are preparing their tooling for the MetaLL ifeŇ and/or TherMaLLifeŇ process. This, in conjunction with NADCAs published E-501Die Care Maintenance Manual, will assist every die caster to obtain performance and extended tool life than was not possible 15 years ago (before the benefits of compressive stress were confirmed and studied.). To see this flow chart in greater detail, click on it Sometimes we are queried about the effect of polishing a die after MetaLL ifeŇ to remove some of the topography. This is especially common for zinc dies where a hardware finish is required. Polishing does not reduce the compressive stress benefit but rather adds slightly to it. Removal of all of the topography, however, will affect the increased lubricity and flow benefits which some die casters, such as magnesium, desire or need. Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained "); array_files[119]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2005-11-BottomLine-Profits.htm","2009-07-17","38K","2005-11 Bottom Line Profits improved with Metallife and Thermallife ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","How to Save Dies for Die Casting by looking at all of the extra intangible costs associated with die maintenance "," 2005-11 Bottom Line Profits improved with Metallife and Thermallife Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Anything underlined in the body maybe clicked toa direct hyperlinkfor more infoClose the hyperlinked box to exit the window and return to this newsletterDiscussed topics are boxed to help reduce the need to scroll pages - read each box as a section. NEWS Bottom Line Profits save this email Print this Newsletter Volume#014-11-05 Badger Metal Tech, Inc. November 2005 Bottom LineROI Click on letters or blue button for more information Send us a casting to get a quote and call us anytime you have a question regarding tool life or extended performance issues. The name of the game is to improve the bottom line. Foreign competition, (forecasted and warned about in our Jan 2003 and Sept 2002 Newsletters), from China and other cheap labor countries are closing down tool shops, die casters, and their customers in the US at an alarming rate. It is not going to get any better. It is more important now than ever before in the history of the United States to protect your bottom line if your company is to survive in todays and tomorrows predatory global markets. For 22+ years Badger Metal Tech has processed 100,000+ dies and has been here to help - particularly the die casting industry. Corporate accounting or upper management sometimes sees only the added cost for our proprietary die surface treatments: MetaLLifeŇ (micro-precision peening) and TherMaLLifeŇ (nitro-carburizing) surface treatments, not the benefits derived. These usually fall into 3 major areas some of which are intangible but definitely affect the bottom line and your profits. Downtim "); array_files[120]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2002-04-validation.htm","2009-07-17","34K","2002-04 Case Western Validation of Thermallife for soldering in die casting dies ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Testing performed by Case Western University to validate the solder resistance ability of Thermallife "," 2002-04 Case Western Validation of Thermallife for soldering in die casting dies Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Continuing in our past footsteps, this is the premierissue of our new electronic newsletter. Anything underlinedmaybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Badger Metal Tech, Inc. for Solder Protection Volume#001-04-2002 April 2002 IN THIS ISSUE 1. Soldering - Causes 2. Substrate Important 3. Lab setup - Test 4. Graphs 5.Summary Case Western has developed an accelerated soldertest to determine theaffinity of various types of steels and surface treatments to molten aluminum It is common knowledge, in the die casting industry, that H-13 dies and other hot work materials containing iron (Fe) will solder or bond to one another. Case Western has developed a means of testing various die materials and surface treatmentsusing a specialacceleratedmethod. Our website has posted some very telling photos of the results of this test using control H-13 material and H-13 +Ther MaLL* ifeÔ Ther MaLL* ifeÔ is a proprietary form of Ferritic nitrocarburizing (FNC)that is performed in a computer controlled fluidized bed. Our machine is the only one of its kind in the US. We have nine stations each with individual capabilities. Once loaded on thesix stationcarousel in a special basket , we start with a computerized alkaline wash to remove all contaminants that could compromise the FNC. This is can be a crucial step in assuring that the diffusion is not disturbed by foreign material on the dies surface. Whetherthe die has apetroleum based or water based rust preventat "); array_files[121]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2003-03-Manufacturing-and-Steel-Issues.htm","2009-07-17","36K","2003-03 Manufacturing and Steel Issues relating to the die casting industry ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Save American Manufacturing efforts to restore the die casting industry "," 2003-03 Manufacturing and Steel Issues relating to the die casting industry Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS Manufacturing & Steel Issues Print this Newsletter Volume#009-04-03 Badger Metal Tech, Inc. April 2003 IN THIS ISSUE 1. Advances in FNC 2. Dievar® 3. Meeting May 2003 We need your letters Facts and Info WI meeting/rally Spread the word Manufacturing In our last issue we called attention to the manufacturing crisis the United States is facing. We encouraged recipients, at that time, to write letters to their Congressmen and Representatives. Since February, there has been a tremendous groundswell from a grassroots organization SAM (Save American Manufacturing). The organization started in IL by Bill Cermak of Pro Mold. Bill saw a need to get organized. SAM is a national organization concerned about the loss in all areas of manufacturing to non-domestic sources that is causing a rapid decline in the economic condition of the United States. Since its founding on December 31st, 2002, SAM has grown to having its own domain and website where everyone in the United States can be reached via the web. SAM ovhas collected over 2000 letters from concerned citizens across the United States and got the attention of the media, and various concerned government officials. 13 State chapters have already been started. Rallies and meetings are planned for Illinois, Wisconsin and Massachusetts. The SA "); array_files[122]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2007-12-changes-newyear.htm","2009-07-17","41K","2007-12 Changes coming in 2008 to Badger Metal Tech ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Badger Metal Tech Metallife and Thermallife are changing to add more benefits for die casting dies "," 2007-12 Changes coming in 2008 to Badger Metal Tech Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS from Badger Metal Tech. Changes for the New Year and some useful gifts Print this Newsletter Volume#022-12-07 Badger Metal Tech, Inc. December 2007 IN THIS ISSUE mouse over & click button Watch for Part II of our article on Residual Stress Affects in the Jan 2008 issue of DCE Part 1 was published in the Sept issue of DCE. You can download here. Ron Karani R&D January 2008 special meeting notice flyer for Chapter 17 directory. One thing that is constant is change. This applies as well to Badger Metal Tech. Here is a preview of what is new, and you will be hearing about in 2008. New Vice President/Owner DCE Part II - Article on Residual Stress Cavitation Effect & Correction Lamination Causes Before Sampling Processing Guarantee +25% or Process cost Refunded Welding + MetaLL ifeŇ 2008 Badger Calendar You can click on any of these topics for more information or use the sidebar buttons to the left. If you want to learn more about Ron Karani, click on his photo in the left sidebar. We have created a page on our website that we call Speedlinks because it tells you everything you need to know about MetaLL ifeŇ and Thermallife Click Here to view Speedlinks Page. Back to top Convert Units of Measurement How many times have you had to convert a dimension or unit but would have to look up a table or use your knowledge of mat "); array_files[123]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2003-02-special-alert.htm","2009-07-17","29K","Alert to the Manufacturing Industry being exported to China ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Trying to warn the US die casting industry about the loss of manufacturing jobs and the Badger Metal Tech web page redesign "," Alert to the Manufacturing Industry being exported to China Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. Print this Newsletter NEWS Special Manufacturing Alert Volume#008-02-03 Badger Metal Tech, Inc. Jan-Feb 2003 This issue is a special alert issue to all of our manufacturing industry.On Jan 28th our President Bush gave his State of the Union Address. Although I support most of his policies, I do not see him or anyone in our government or the mass media really understanding what is causing our economys lack of recovery. Anyone concerned about our economy and the realization of the threat that China poses, should scroll down to the section below. This information is always updated to include new articles and topics relative to this problem. Click on the link below Sold American Manufacturing to view current Information on this issue with posted articles. In addition to this very important information, we also are announcing our New Updated Web page that has been split into two separate sections: One for Die Casting, and one for Draw Form / Blanking. We have added convenient buttons for navigation purposes. Quickly you can jump from Metallife to Thermallife information for your specific needs. The information is specific to each type of die tooling. Hot Work for Die Casting and Forging. Cold Work for Draw Form / Blanking. Badger New Website Here is a sample of our buttons: www.badgermetal.com This takes y "); array_files[124]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2006-05-nadca-diecare-manual.htm","2009-07-17","35K","2006-06 NADCA die casting manuall for maintenance of die casting dies ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Excerpts from the NADCA Die Care Maintenance manual using Metallife to increase tool life for die casting dies "," 2006-06 NADCA die casting manuall for maintenance of die casting dies Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS NADCA Revised Die Care Manual Catalog Item E-501 April 2006 Print this Newsletter Volume#016-05-06 Badger Metal Tech, Inc. May 2006 IN THIS ISSUE Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[125]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2005-09-Web-Quoting.htm","2009-07-17","36K","2005-09 Quoting on the Web Quotes & Laser Stressing ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","How to get a die casting die quote for Metallife and Thermallife along with recent advancements by laser peening "," 2005-09 Quoting on the Web Quotes & Laser Stressing Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Anything underlined in the body maybe clicked toa direct hyperlinkfor more infoClose the hyperlinked box to exit the window and return to this newsletterDiscussed topics are boxed to help reduce the need to scroll pages - read each box as a section. NEWS Web Quotes & Laser Stressing Print this Newsletter Volume#013-05-05 Badger Metal Tech, Inc. September 2005 Web QuotingDie Casting1. Long Form Die Cast2. Short Form Die Cast Web QuotingDraw/Form/Stamp3. Long Form D/F/S4. Short form D/F/S.TherMaLLifeŇ5. Thermallife Steel ID6. Important to know7. More detail w/ photosLaser Stressing1. Case Western Sample2. Short Laser VideoLet us know what other information you need. We will provide you with the link.Call us anytime you have a question regarding tool life or extended performance issues. <<FirstName>>, progressive companies such as <<Company>> are always looking for new technology. So it is with Badgers proprietary MetaLLifeŇ process. See the side bar to learn more about how LaserLife (laser peening) is now being commercially done to aviation components. Case Western has just started an evaluation to discover the additional benefits that LaserLife might provide in the case of perishable tooling, especially die casting dies. Badger prides itself on having one of the quickest service responses in the industry. We also understand that sometimes time zone or hour differences can protract a response for a quote. To address this problem, we now offer an online form that can be filled out and emailed to us. Use the short form, if you will "); array_files[126]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2006-09-packaging.htm","2009-07-17","33K","2006-09 Packaging die casting dies and tools to prevent damage in shipment ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","How to prepare tooling for shipment to Badger Metal Tech and avoid damaged die casting dies "," 2006-09 Packaging die casting dies and tools to prevent damage in shipment Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS Packaging Odds and Ends Print this Newsletter Volume#017-09-06 Badger Metal Tech, Inc. September 2006 IN THIS ISSUE We would like to thank all of our customers for their continued business. It is your encouragement that contributes to the phenomenal growth and demand for Metallife and our exclusive Thermallife process. Now we have your company covered for the 4 most common modes of your die failure - Thermal Fatigue Heat Checking, Washout, Erosion, and now through Thermallife - solder protection. Since 1994, Badger has been publishing our newsletter relating to our processes, die materials and associated topics. These newsletters are all available on our website: Since our newsletter creation we have covered many topics relating to die casting and die materials. In one issue, we discussed how to make sure that your tooling reaches us in a good condition. For your convenience we are recapping the high points contained in this 1997 newsletter.Click on the sidebar buttons to view the information applicable to the topic. Back to top Watch for our new ad in NADCAs Die Casting Engineer magazine. WEVE GOT YOU COVERED ! Back to top back to topics Is there a way to have Internet Explorer open as a maximized window? If you are like most web users, it can be extremely annoying to constantly h "); array_files[127]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2004-06-Drawing-Forming-Stamping.htm","2009-07-17","35K","2004-06-New-Treatments-for-extending the life of Drawing-Forming-Stamping ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Surface treatments for tooling including die casting dies along with drawing forming and blanking tooling "," 2004-06-New-Treatments-for-extending the life of Drawing-Forming-Stamping Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked Newly opened window to exit and return to this newsletter NEWS Topic: NEW Surface treatments for Cold Work Steel Tooling Volume#010-06-04 Badger Metal Tech, Inc. June 2004 IN THIS ISSUE 1. Metallife 2. MetallifeMainPg 3. FAQs Metallife 4. Pricing Metallife 1. Thermallife 2. ThermallifeMainPg 3. FAQs Thermallife 6. Pricing Thermallife Combining Processes 7. About Us 8. Contact us 9. Delivery Info click on graph For over 20 years, Badger Metal has been servicing the die casting industry and showing how to extend tooling life and improve the performance of die casting dies by utilization of the MetaLL ifeŇ and TherMaLLifeŇ processes Now after extensive field and lab tests, the process has been modified to include application to cold work tool steels such as D2, A2, CPMV and others. These Badger processes are not a coating or plating as is commonly being used in the industry today. Both processes are unique and superior to coatings in that: 1. They do not wear off with time. 2. There is no heat involved with the MetaLL ifeŇ process. 3. There are no line of site limitations with TherMaLLifeŇ. 4. Both processes induce compressive stresses that counter fatigue failures in tool steel. 5. In some applications it is possible to combine both processes for added benefits.. More information can be obtained by clicking on the side bar topics. Call us to sample our service. back to top Badger Metal Tech, Inc. N60 W15088 Bobolink Ave. Menomonee "); array_files[128]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2007-06-NADCA-guides.htm","2009-07-17","36K","2007-06 Weld Repair Stress Correction with Metallife and heat stress tempering ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","The effect that Metallife has to welded areas of die casting dies "," 2007-06 Weld Repair Stress Correction with Metallife and heat stress tempering Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS NADCA User Guides - Free to Corporate Members Print this Newsletter Volume#020-06-07 Badger Metal Tech, Inc. June 2007 IN THIS ISSUE User Guide Links NADCA has just published a NEW users guide - (Relieving Stress in Die Casting Dies) by using Heat Stress Temper and MetaLL*ifeŇ. This new guide includes a technical overview of die casting die stress, heat checking causes, and the methods used to combat them. In addition there are test results conducted by Oak Ridge National Laboratory which support the positive effect of inducing MetaLL*ifeŇ compression to extend die life. Besides this there are two other useful User Guides also available from NADCA. Corporate Members can obtain 1ea copy of these plus many other publications FREE by just logging onto the NADCA website. The sidebar buttons in the newsletter are direct links to the NADCA site and the specific page where these User Guide publications can be ordered. With these in hand, die casters now have FREE access to the three key ingredients for extending tool life. First choose a quality certified die steel, heat treat it correctly, then relieve the residual tensile stress build up, that shortens die life, by using heat stress tempering followed by MetaLL*ifeŇ. Finally care for the tool by following the recommended maintenance "); array_files[129]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2004-10-Magnesium-Flow.htm","2009-07-17","32K","2004-10 Magnesium die casting die flow improvement ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Why Metallife when applied to die casting dies improves the flow of molten metal for both aluminum and magnesium die casting dies "," 2004-10 Magnesium die casting die flow improvement Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS Improving the Flow for Magnesium Castings Print this Newsletter Volume#011-10-04 Badger Metal Tech, Inc. October 2004 IN THIS ISSUE 1. Metallife Benefits 2. Molten Metal Flow 3. Topography 4. Badger Sample Casting 5. FAQ EMAIL Us Contact Us A recent article in Die Casting Engineer magazine (Sept 2004 p40) discusses the problem facing magnesium die casters relating to cavity fill. In the article, solidification analysis is discussed along with its relationship to trapped gases that affect porosity levels. These trapped gases negatively affect the casting quality and integrity. Magnesium is the metal of the future NOW. More automotive components and parts are being made from this plentiful material to reduce vehicle weight without reducing strength. As a member of the magnesium die casting community, we want to make you aware of two benefits that MetaLL ifeŇ provides that relate directly to this problem. The MetaLL ifeŇ resultant dies topography provides a mechanism that enhances metal flow and at the same time helps break up the trapped gases in the molten magnesium metal. Magnesium castings, in most instances, are thinner than aluminum. Magnesium pour temperature is also lower, which is a benefit in reducing thermal cracking. Back to top As the metal flows into a magnesium die, the lower temperature cause "); array_files[130]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2006-03-Another-Validated-Benefit.htm","2009-07-17","34K","2006-03-Another-Validated-Benefit insulating benefits with Metallife for die casting dies ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Metallife helps insulate the surface of the die from direct contact with the molten metal thus lowering the surface temperature and increasing die casting die life "," 2006-03-Another-Validated-Benefit insulating benefits with Metallife for die casting dies Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS More Benefits Confirmed<We trust you find this useful Print this Newsletter Volume#015-03-06 Badger Metal Tech, Inc. March 2006 IN THIS ISSUE1. Case Western Test2. Request the DMC-CD3. UltraPolishing4. Badger Brochures Internet Explorer Tech Tip At the recent February 2006 meeting of the Die Materials Committee in Chicago, Case Western submitted a report on studying the insulating effect of die lubricant build-up. Their findings, utilizing the standard dip tank procedure, showed that during the die casting operation that a residual insulating film builds on the surface of the 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. This promotes longer die life. We already know that the MetaLL ifeŇ process and its compressive stress layer prevents propagation of existing heat checking. We also have validated that the MetaLL ifeŇ topography retains lubricant and prevents soldering. Now from Case Westerns findings yet another benefit surfaces for die casting dies.. Our enhanced lubricant retention property lowers the die surface temperature helping to further extend tool life. A more detailed report including graphs is available on our website. Click here or use the "); array_files[131]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2007-01-search-and-repair.htm","2009-07-17","35K","2007-01 Search engine for Badger Metal Tech ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","A web search engine to find out everything to know about die casting die materials and maintenance of die casting dies "," 2007-01 Search engine for Badger Metal Tech Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS Badger 2007 - Search and Repair Print this Newsletter Volume#018-01-07 Badger Metal Tech, Inc. January 2007 IN THIS ISSUE Tom Peters said Excellent firms dont believe in excellence - only in constant improvement and constant change. 2007 will be another year of change and improvement for Badger Metal Tech. We are proud to mark the beginning of Badger Metals 24th year in business. This year you will see some significant changes in how you treat die cast tooling for protection from soldering. Rest assured that Badger Metal Tech remains committed to providing this protection even though your previous source may have gone out of business. Look to TherMaLLifeŇ to fill these requirements. Badgers web site was launched in 1996 and since that time has grown to over 250 pages of information. One of the issues we have had to deal with is helping you find the information you want quickly without spending a lot of time opening various pages. We are pleased to announce in 2007 our new java search engine that functions much like a Google search with more changes to come. You will find our familiar green and black button on many of our pages including our home page. Once you click on this buttom, you can then do a specific search for any type of document, page, file, etc. Try it. Our goal is to help you zero in on any topic or "); array_files[132]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2004-06-Die-Casting.htm","2009-07-17","35K","2004-06-Recapping-Die-Casting-benefits of Metallife and Thermallife ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","A review along with Frequently Asked Questions (FAQ) on the benefits of doing Metallife and Thermallife to die casting dies and other tooling "," 2004-06-Recapping-Die-Casting-benefits of Metallife and Thermallife Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Underlinedtext in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked Newly opened window to exit and return to this newsletter An archive of all our newsletters are posted at: Newsletter Summaries NEWS Topic: Recapping Benefits Volume#010-06-04 Badger Metal Tech, Inc. June 2004 IN THIS ISSUE 1. Metallife 2. MetallifeMainPg 3. FAQs Metallife 4. Pricing Metallife 1. Thermallife 2. Thermallife - DieVar 3. FAQs Thermallife 6. Pricing Thermallife Combining Processes 7. About Us 8. Contact us 9. Delivery Info click on graph For over 20 years, Badger Metal has been servicing the die casting industry and showing how to extend tooling life and improve the performance of die casting dies by utilization of the MetaLL ifeŇ and TherMaLL ifeŇ processes Extensive field and lab data has been compiled confirming the benefits of both processes. Larger customers are able to access this information via custom built web pages specific to their product and part numbers. This newsletter is a short recap of the properties and expected benefits. offered by both processes. Keep this email and use it as a quick reference whenever you wish to find out more about MetaLL ifeŇ or TherMaLLifeŇ. By clicking on the sidebar text, you can access specific areas on the Badger Metal web site. Badger is proud to say We Employ America. Watch for our New Ad in The Die Casting Engineer magazine. Call us if you have any further questions. back to top Badger Metal Tech, Inc. N60 W15088 Bobolink Ave. Menomonee Falls, Wisconsin 53051 Phone: 262-252-3804 "); array_files[133]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2004-10-Aluminum-Flow.htm","2009-07-17","33K","2004-10 Aluminum flow benefits using Metallife for die casting dies ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Why Metallife when applied to die casting dies improves the flow of molten metal for both aluminum and magnesium die casting dies "," 2004-10 Aluminum flow benefits using Metallife for die casting dies Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS Improving the Flow for Aluminum Castings Print this Newsletter Volume#011-10-04 Badger Metal Tech, Inc. October 2004 IN THIS ISSUE 1. Metallife Benefits 2. Molten Metal Flow 3. Topography 4. Badger Sample Casting 5. FAQ Testimonies EMAIL Us Contact Us A recent article in Die Casting Engineer magazine (Sept 2004 p40) discusses the problem facing magnesium die casters relating to cavity fill. In the article, solidification analysis is discussed along with its relationship to trapped gases that affect porosity levels. These trapped gases negatively affect the casting quality and integrity. Although magnesium is being used more and more, many aluminum parts are still being produced especially for automotive components. As a member of the general die casting community, we want to make you aware of two benefits that MetaLL ifeŇ provides that relate directly to this problem in both magnesium and aluminum castings. The MetaLL ifeŇ resultant topography change provides a mechanism that enhances metal flow and at the same time helps break up the trapped gases in the molten metals thereby reducing porosity concentrations. Magnesium castings, in most instances, are thinner than aluminum. Magnesium pour temperature is also lower than aluminum, which is a benefit in reducing thermal cracking. Back to to "); array_files[134]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2007-03-weld-repair-stress.htm","2009-07-17","38K","2007-03 Weld Repair Stress Correction with Metallife to reduce tensile stresses ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","How combining Metallife with heat stress tempering can improve the life of die casting dies and welded areas "," 2007-03 Weld Repair Stress Correction with Metallife to reduce tensile stresses Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS Weld Repair & The Stress Correction Print this Newsletter Volume#019-03-07 Badger Metal Tech, Inc. March 2007 IN THIS ISSUE NADCAs newest heat treat spec 207-2006 has a two page section discussing the guidelines for proper weld repair or correction welding. Everything from the aspect of heat affected zone, die prep, procedure, preheat, and post stress temper guidelines are carefully spelled out. One very important step that is missing, however, is a discussion of how the weld affects the integrity of the tool and preventative steps that should be taken to relieve the resultant tensile stresses. MetaLL*ifeŇ is extremely beneficial in removing the undesirable tensile stresses that affect welded areas. As you read the explanation of the causes of these weld stresses, please refer to the graph shown below. Our recommendation is to make sure that any welded tool is heat stress tempered and then subsequently followed by an application of the MetaLL *ifeŇ process to provide the benefits mentioned. Back to top Residual tensile stress from welding is created because the weld consumable is applied in its molten state. This is its hottest, most expanded state. It then bonds to the base material, which is much cooler. The weld cools rapidly and attempts to shrink during the cooling. Becau "); array_files[135]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2007-09-cavitation.htm","2009-07-17","38K","2007-09 Metallife will help reduce cavitation effect that leads to metal breakout in die casting dies ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","A newly discovered mode of die failure - metal breakout erosion and lamination are caused by cavitation while filling "," 2007-09 Metallife will help reduce cavitation effect that leads to metal breakout in die casting dies Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS Cavitation Effect Study of Breakout and Lamination Print this Newsletter Volume#021-09-07 Badger Metal Tech, Inc. September 2007 IN THIS ISSUE User Guide Links Watch for the first part of a two part article on Residual Stress Affects in the Sept 2007 issue of DCE 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 h "); array_files[136]=new Array(0,1,"http://www.badgermetal.com/newsletters/1997-06.htm","2009-07-17","9K","Newsletter - 1997-06 Odds and Ends - Packaging ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 1997-06 Odds and Ends - Packaging Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Print this Newsletter This is an archived page and cannot be changed "); array_files[137]=new Array(0,1,"http://www.badgermetal.com/newsletters/1999-02.htm","2009-07-17","9K","Newsletter - 1999-02 Residual Stress Measurements ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 1999-02 Residual Stress Measurements Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Print this Newsletter This is an archived page and cannot be changed "); array_files[138]=new Array(0,1,"http://www.badgermetal.com/newsletters/1999-04.htm","2009-07-17","9K","Newsletter - 1999-04 Improvements and Developments ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 1999-04 Improvements and Developments Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Print this Newsletter This is an archived page and cannot be changed "); array_files[139]=new Array(0,1,"http://www.badgermetal.com/newsletters/emailbmt/2005-05-100,000-Strong.htm","2009-07-17","39K","2005-05 Over 100,000 dies for die casting and other tooling processed with Metallife and Thermallife ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","The why and how of die casting die failure and corrective action to repair die casting dies with Metallife "," 2005-05 Over 100,000 dies for die casting and other tooling processed with Metallife and Thermallife Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Anything underlined in the body maybe clicked toa direct hyperlinkfor more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to help reduce the need to scroll pages - read each box as a section. NEWS 100,000+ Tools & Going Strong Print this Newsletter Volume#012-05-05 Badger Metal Tech, Inc. May 2005 Badger Web Industry Related 1. Blanking Tests 2. Drawing Form Tests 3. Newsletters Past 4. FNC Nitrogen Dissoc. 5. Coating Adhesion Case Western 1. Case Solder Test 2..Validate Compression 3. Tool Steel Testing 4. Solder Test pps 5. Shot Sleeve Testing 6. Critical Apps Steel DMC (large files) Web Server Info 1. Powerpoint Reports 2. Acrobat pdf Reports MetaLL ifeŇ 1. FAQ 2. Compliancy Issues 3. Field Results 4.Draw Forming 5.Blanking/Stamping TherMaLLifeŇ 1. NADCA DCE Article 2. FAQ 3. Rield Results 4. Draw Forming 5. Blanking Let us know what other information you need. We will provide you with the link. Periodically we will provide new links as we receive and post new information Save these emails and call us anytime you have a question regarding tool life or extended performance issues. During our 22 years, Badger has learned a lot about what causes die cast and perishable tooling failure along with what corrective and preventative actions to take. Through a long standing participation in NADCAs Die Materials Committee (DMC) and Task Force Chairs, Badger has captured this knowledge so we can share it with our customers and potential clients. Countl "); array_files[140]=new Array(0,1,"http://www.badgermetal.com/newsletters/1994-08.htm","2009-07-17","25K","1994-08 Compressive Stress Depths using Metallife on die casting dies ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Compressive stress curves for die casting dies using Metallife "," 1994-08 Compressive Stress Depths using Metallife on die casting dies Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com August 1994 Bulletin Compressive Stress Depth Print this Newsletter Click Here to see Coupon Lambda X-Ray Diffraction Curves Taken in June 1997 Tensile residual stresses are a factor on used tooling running production die cast parts as well as on NEW tooling that only has been sampled for production. After a NEW tool receives its final tempering, there still remains tensile stresses on the surface of the steel. These stresses, if left untreated, can cause premature initiation of thermal heat checking. It is important for a die caster to be aware of this condition so that the necessary corrective action can be taken to counteract it. Inducing a uniform depth of residual compressive stress on a dies surface is a critical step to extending the life of the tool, especially in the case of EDM production methods. Cracks originate at the surface of a die and propagate from the outside into the surface. A uniform compressive stress layer on the tools surface will not allow the propagation of a crack into or through this compressive layer unless the effective yield strength of the steel is exceeded. This is a fact of metallurgical engineering and is the principle upon which MetaLL ifeŇ is based. In this test we measured, by using X-ray diffraction using PROTO portable measuring equipment, the depth and degree of compressive stress for each of our T processes. For our test specimen we used one of our sample Viscount (Rockwell 44c) bars. This bar is identical to the one that many of our customers and potential users already have in their posses "); array_files[141]=new Array(0,1,"http://www.badgermetal.com/newsletters/1998-04.htm","2009-07-17","9K","Newsletter - Residual Stress Part 3 ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - Residual Stress Part 3 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Print this Newsletter This is an archived page and cannot be changed "); array_files[142]=new Array(0,1,"http://www.badgermetal.com/newsletters/1997-02.htm","2009-07-17","16K","Newsletter - 1997-02 Modes and Causes of Die Failure - Part 2 ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 1997-02 Modes and Causes of Die Failure - Part 2 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Print this Newsletter Badger Metal Tech, Inc. N60 W15088 Bobolink Ave. Menomonee Falls, WI 53051 262-252-3804 FAX 262-252-3956 TOLL FREE in the United States and Canada - 800-366-1973 Volume 4 Issue 2 Modes & Causes of Die Failure Part 2 February 1997 In Part 1 of our series on “Modes and Causes of Die Failure” we began our examination of Stress and Thermal Fatigue by discussing die heat checking. We also know that Gross Cracking is another type of failure which is usually catastrophic and caused by the die material’s loss of toughness. The above statement identifies and explains some contributing factors that can exacerbate gross cracking failure. Unfortunately, sometimes design requested criteria or needed dimensions and tolerances as specified by end user drawings and prints call out sharp corners or edges. These sharp corners, are, by nature, high stress areas. As a result, gross cracks are more likely to start in these areas. For this reason, wherever possible, inside and outside tooling corners and edges should be designed to have radii. A general rule of thumb for hardness is: Harder dies are more prone to gross cracking. Conversely lower rockwells are less likely to gross crack but too low of hardness can cause the tool to prematurely heat check. The optimum for dies is anywhere between45-48Rc. Sometimes larger inserts tend to have lower than 45Rc hardness. The reasoning behind this is that gross cracking of large tools is more costly than heat checking. Smaller inserts conversely are sometimes targeted to higher than 48Rc to protect against heat checking whichis sometimes unacceptable for intricate and small design configurations. It is important to note that ro "); array_files[143]=new Array(0,1,"http://www.badgermetal.com/newsletters/1998-02.htm","2009-07-17","8K","Newsletter - Residual Stress Part 1 ","",""," Newsletter - Residual Stress Part 1 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Print this Newsletter This is an archived page and cannot be changed "); array_files[144]=new Array(0,1,"http://www.badgermetal.com/newsletters/2000-03.htm","2009-07-17","9K","Newsletter - 2000-03 Residual Stress Part 2 ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 2000-03 Residual Stress Part 2 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Print this Newsletter This is an archived page and cannot be changed "); array_files[145]=new Array(0,1,"http://www.badgermetal.com/newsletters/1995-11graphs.htm","2009-07-17","21K","Surface finish graphs for Metallife processes ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Surface finish graphs for Metallife processes Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com November 1995 Bulletin - Typical Casting Surface Finish 47Rc (Updated Graphs - December 2008 ) Surface finish Return to previous Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[146]=new Array(0,1,"http://www.badgermetal.com/newsletters/1997-04.htm","2009-07-17","29K","Newsletter - 1997-04 Modes and Causes of Die Failure - Part 4 ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 1997-04 Modes and Causes of Die Failure - Part 4 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Print this Newsletter Badger Metal Tech, Inc. N60 W15088 Bobolink Ave. Menomonee Falls, WI 53051 262-252-3804 FAX 262-252-3956 TOLL FREE in the United States and Canada - 800-366-1973 Volume 4 Issue 4 Modes & Causes of Die Failer Part 4 April 1997 The most significant attributes that are needed for dies used for die castingor squeeze casting are: Resistance to thermal fatigue. - Minimize softening of die. - High fracture toughness. - Removal of residual stress. Other properties such as erosion/washout reduction and soldering resistance are also important, but can be influenced more by die filling conditions and statistical process controls. We will discuss in future bulletins additional benefits of MetaLL ifeŇ that also help in these areas. In the previous March issue ofour newsletter, we began our discussion of the “K” value formula and how the parameters presented affect die thermal fatigue.The higher the “K” value, the more resistance to thermal fatigue.. Examining the formula we see that increased thermal conductivity and yield strength are directly proportional to obtaining optimum K values while thermal expansion and modulus of elasticity properties are in directly proportional to a high “K” value. Almost all premium grades ofH-13 steel have sufficient percentages of molybdenum ranging anywhere from .90% to 1.85%. Martensitic steels are fairly good for both a high thermal conductivity and low thermal expansion, while austenitic superalloys are not as good. The modulus of elasticity is difficult to change. High yield strength should be "); array_files[147]=new Array(0,1,"http://www.badgermetal.com/newsletters/1995-06.htm","2009-07-17","24K","Newsletter - 1995-06 Case Western DCE Article ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 1995-06 Case Western DCE Article Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Die Casting Engineer Magazine Article Excerpt Print this Newsletter Mar/Apr 1995 Issue John Wallace Improvement of Die Life in Aluminum Die Casting Dr. David Schwam and Professor John Wallace Case Western Reserve University Cleveland, Ohio Die Surface Treatments Section The use of the die surface modification known as the MetaLL ifeŇ treatment - also extends die life, because it replaces the residual tensile stresses that develop on the die surface with compressive stresses. The die is processed initially and then periodically (every 10,000 to 20,000 die cycles), thereafter. Thermal stress relieving the used die at 50 degrees F under the highest tempering temperature also is used. Studies using the thermal fatigue immersion specimen have demonstrated that MetaLL ifeŇ and thermal stress relieving have reduced thermal fatigue cracking. The effective use of these methods is to apply these procedures during the life of the die. The die is removed from service periodically processed to reduce the tension residual stress at the surface and returned to use. Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[148]=new Array(0,1,"http://www.badgermetal.com/newsletters/1994-10.htm","2009-07-17","24K","Newsletter - 1994-10 Justifying Stress Tempering ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 1994-10 Justifying Stress Tempering Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com October 1994 Bulletin Justifying Stress Tempering Print this Newsletter Most die casters are constantly under pressure to keep up with increasing demand for their customers production requirements. Quite often these demands allow very little time for preventative maintenance procedures that would normally be followed. Residual tensile stresses in tooling continue to build with the use of the die. If these internal and surface stresses are not normalized by heat stress tempering and then encapsulated by MetaLL ifeŇ, die life is significantly affected. Skipping either of these usually will manifests shortened tool life. The die caster or end user incurs additional cost for new tooling or subsequent repair of the used tooling to fix conditions that could have been avoided by a proactive maintenance program. In the long run, nothing is gained by meeting production requirements at the expense of the tooling. Thermal Heat Stress Tempering Every die caster knows that periodic heat stress tempering will help to extend a tools life. Quite often, however, production requirements do not allow time to have this done. Badger Metal now offers this service in conjunction with having the die MetaLL ifeŇ processed. When sending tooling to us for processing simply state on the paperwork or call and let us know that the inserts are to be stress tempered prior to MetaLL ifeŇ. We will handle the rest. We use an outside certified source performs this service for us on a one day basis. Depending on the size and amount of inserts involved this can add 1 to 1 1/2 days to our nor "); array_files[149]=new Array(0,1,"http://www.badgermetal.com/newsletters/1998-03.htm","2009-07-17","9K","Newsletter - Residual Stress Part 2 ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - Residual Stress Part 2 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Print this Newsletter This is an archived page and cannot be changed "); array_files[150]=new Array(0,1,"http://www.badgermetal.com/newsletters/1997-01.htm","2009-07-17","28K","Newsletter - 1997-01 Modes & Causes of Die Failure - Part 1 ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 1997-01 Modes & Causes of Die Failure - Part 1 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Print this Newsletter Badger Metal Tech, Inc. N60 W15088 Bobolink Ave. Menomonee Falls, WI 53051 262-252-3804 FAX 262-252-3956 TOLL FREE in the United States and Canada - 800-366-1973 Volume 4 Issue 1 Modes & Causes of Die Failure - Part 1 January 1997 Badger Metal Tech’s continued association with NADCA’s Die Materials Committee has given us considerable insight into some of the problems and possible solutions that are being addressed by this group of dedicated people and organizations. One of the most costly of these is the premature failure of die cast die tooling. This is so much of a concern that the focus of the Die Materials Committee is dedicated to addressing just this issue - IMPROVING THE LIFE OF DIE MATERIALS. A number of avenues present themselves as a result of this focus, however, it would be impossible to address all of these in this condensed bulletin. Instead, in this and the following special issues, we will focus on a discussion of the modes and causes of die failure in an attempt to further educate the die casting community and at the same time offer some solutions that are readily available using current technology and procedures. To do this and remove a couple of variables from the equation, it is necessary to make a few assumptions1) The proper H-13 material has been selected using the current#207-90 specification. 2) The EDM and/or machining of the tool has been properly accomplished and the white cast layer has been removed.3) The heat treatment has been certified to conform to NADCA specifications to not only attain "); array_files[151]=new Array(0,1,"http://www.badgermetal.com/newsletters/add-remove/newsletter-remove.htm","2009-07-17","21K","Newsletter Subscribe ","",""," Newsletter Subscribe Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Newsletter Unsubscribe/Subscribe Please take the appropriate action regarding my subscription. enter your current email address Please remove this email address from your newslettermailing for now Please add me to your newsletter mailing Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[152]=new Array(0,1,"http://www.badgermetal.com/newsletters/1997-08.htm","2009-07-17","9K","Newsletter - 1997-08 Modes and Causes of Die Failure - Part 5 ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 1997-08 Modes and Causes of Die Failure - Part 5 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Print this Newsletter This is an archived page and cannot be changed "); array_files[153]=new Array(0,1,"http://www.badgermetal.com/newsletters/1998-12.htm","2009-07-17","20K","Newsletter - Residual Stress Part 5 ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - Residual Stress Part 5 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Print this Newsletter This is an archived page and cannot be changed Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[154]=new Array(0,1,"http://www.badgermetal.com/newsletters/2001-12.htm","2009-07-17","20K","Newsletter - Announcing Thermallife ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - Announcing Thermallife Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Print this Newsletter Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[155]=new Array(0,1,"http://www.badgermetal.com/newsletters/1995-11.htm","2009-07-17","37K","Newsletter - 1995-11 Casting Surface Finish ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Newsletter - 1995-11 Casting Surface Finish Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com November 1995 Bulletin - Typical Casting Surface Finish 47Rc (Updated December 2008 ) Print this information Click on image for enlarged view Casting produced from 47Rc H-13 tool steel Averages with .030 of travel Averages with .100 of travel Process Micro inch Ra Micro meters Ra Process Micro inch Ra Micro meters Ra T-21 56.6 1.445 T-31 75.35 1.915 T-41 64.9 1.655 T-40 68.75 1.755 T-40 89.55 2.275 T-41H 101 2.57 T-41H 188 4.78 T-40H 171.15 4.35 T-40H 200 5.06 T-60 58.02 1.475 T-60 76.65 1.95 T-61 60.5 1.54 T-70 71.9 1.83 T-71 65.55 1.665 T-71 66.85 1.70 Users of the MetaLL ifeŇ process are already familiar with the varying degrees of compressive stress that may be induced and the resulting approximate topography produced from these T processes as they are called. As a rule of thumb for a given die hardness the amount of topography change is directly proportional to the relative degree and depth of compressive stress. The higher the T value, the more compressive stress that is induced. A frequently asked question in conjunction with this is what surface ra can be expected from these different processes on the casting? The chart graph above shows the various surface finishes that were taken from a casting produced from H-13 with a 47Rc hardness. This same topography can be expected on other steels with similar hardness. When applied to Cold work steels, since they are much harder (avg 58-62Rc), surface finish of the tool has never been a problem or concern. In 1995 we took profilometer readings for surface topography of the various MetaLL ifeŇ finishes using a "); array_files[156]=new Array(0,1,"http://www.badgermetal.com/speedlinkM.htm","2009-07-17","24K","Speedlink - Quick Summary Info on Metallife ","",""," Speedlink - Quick Summary Info on Metallife Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Welcome to our SPEEDLINKS page Here are the latest MetaLL ifeŇ SPEEDLINKS that will direct you to specific information on our web site. Just click on the underlined words to find the information you are looking for on our site. Each time you do this you will be taken directly to the requested information. If we can be of any further assistance please call us. You may also use the above search engine button to find specific information or files. Click Here for the MetaLL ifeŇ benefits Frequently Asked Questions on MetaLL ifeŇ Our shipping, mailing, fax, phone, and email info - Addresses Download Brochures, Printed Information, Slide Shows, NADCA reports, etc. Before and After Photos of severely heat checked die casting die. Pricing and Leadtimes and Services Our Certificate of Compliance and what it entails History of our Company Lambda X-Ray Diffraction Curves for all T processes Compressive Curves - Compressive surface topography The NEW science behind breakout cause and effect. Residual Stress Testing by Case Western University using polished only specimen Understanding Residual Stress Effect to Die Casting Dies and Corrective Action Feedback on How are we doing? Validation by Case Western Lab Tests - Diptank EDM Results Latest News Releases and Testimonies Preview Badger Metal Sample Casting - Viewing Requesting Combining benefits of MetaLL ifeŇ and TherMaLLifeŇ Case Western Reserve University The Ohio State University Click Here or the top green button to view the TherMaLLifeŇ Speedlinks Page SPEEDLINKS: This page, if needed, should be forwarded to customers, clients, or other personnel in your company. Thank you for allowing us to be of continued assistance. Jerry Skoff - President P "); array_files[157]=new Array(0,1,"http://www.badgermetal.com/dmc-dc-care-manual.htm","2009-07-17","73K","Die Care Maintenance Manual 2006 Summary ","",""," Die Care Maintenance Manual 2006 Summary Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Care and Maintenance of Die Casting Dies Manual and Checklist 2006 Excerpts Cost - 60 non-members - 45 Individual - 30 Corporate purchase from NADCA enter E-501 for search criteria table of contents - click on section *(MetaLLifeŇ) is a registered service mark for micro-precision peening process *(TherMaLLifeŇ) is a registered service mark for nitro-carburizing Proper Care for Longer Life - Production Die Cast Dies - Pages 14-15 Preventative Maintenance Program - Page 17 Squeezing More Runs Out of Worn Out Dies - Pages 29-30 web sections Proper Care for Longer Life - Production Die Casting Dies Always Preheat Stress Relieve MetaLLifeŇ TherMaLLifeŇ Perform regular die maintenance Control Die Temperature Control Metal Temperatures Run Die Consistantly Water Lines nitro carburizing (TherMaLLifeŇ) micro-precision peening (MetaLLifeŇ) Heat Check Avoidance MetaLLifeŇ TherMaLLifeŇ Other Recommendations - Continued in NADCA manual E-501 return to table of contents Proper Care for Longer Life - section You have made an excellent die design, purchased the best steel, custom heat treated the steel to achieve the ultimate properties, had the die built by your best toolmaker and of course the gate and runner are good. You have sampled it and obtained piece approval. Now you expect a long die life. The following are some guidelines that have shown to be effective methods to maximize die life. These are tried and proven techniques being used by die casters and die shops throughout the world. Always Preheat Never make a shot on a cold die. When preheating, do not overheat thin "); array_files[158]=new Array(0,1,"http://www.badgermetal.com/bmtcurves/lambda-ml-plus-tl-combined-curves-r.htm","2009-07-17","29K","Metallife and Thermallife combinations for extending die casting die life and improving performance of die casting dies and other molds. ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","A composite graph showing various combinations of Metallife and Thermallife resulting compression "," Metallife and Thermallife combinations for extending die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com The below graph shows a single combined graph of the three means of processing with MetaLL ifeŇ (T-41 or T-41H) and TherMaLLifeŇ (TL06 or TL08). From the graph it can be seen that the black curve has both the highest surface compression and maximum compressive values with no topography to the tool steel. The TherMaLLifeŇ + T-41H processing also can be done without any danger of spalling the epsilon compound layer, however, customers that prefer a topography will perform the MetaLL ifeŇ first . For more information regarding combining processes, please see our coupon photo page. Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[159]=new Array(0,1,"http://www.badgermetal.com/bmtcurves/lambda-metallife-curves.htm","2009-07-17","25K","Metallife compression curves for extending die casting die life and improving performance of die casting dies and other molds. ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Metallife compression curves showing various depths of compression using the different processes along with a composite curve for all processes "," Metallife compression curves for extending die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Why we use Lambda? Lambda X-Ray Diffraction Curves for MetaLL ifeŇ Processes (1000psi = 1ksi = 6.9mpa = 6,895,000pa) T-21min through T-71max (Now includes T-41H Process) Compressive Stress Values as a function of Depth Click here - to view surface topography after MetaLL ifeŇ Taken June 1997 values above 0 on the y axis show tensile stress - allows crackings values below 0 on the y axis show compressive stress - stops cracking VALUES FROM H-13 COUPON SAMPLES HARDENED TO 44-46Rc T-21 - Some compression but shallow depth Application - Core Pins and Zinc Dies T-41 - Good compression and depth T-41H - High compression and maximized depth More topography than T-41 depth PREFERRED BY MOST CUSTOMERS T-61 - High surface compression and depth More topography than T-41 T-71 - High surface compression and depth More topography than T-61 View a Composite Curve of T-41 thru T-71 Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[160]=new Array(0,1,"http://www.badgermetal.com/cavitation-slideshow.htm","2009-07-17","39K","PowerPoint Cavitation Presentation ","",""," PowerPoint Cavitation Presentation Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com PowerPoint Cavitation Slide Presentation To navigate this slide show of 32 images 1. Click on the thumbnails (small images) from left to right. 2. Use the right and left arrows (clear) on the screen to scroll the images. layer visibility=hide Slide 1Slide 2Slide 3Slide 4Slide 5Slide 6Slide 7Slide 8Slide 9Slide 10Slide 11Slide 12Slide 13Slide 14Slide 15Slide 16Slide 17Slide 18Slide 19Slide 20Slide 21Slide 22Slide 23Slide 24Slide 25Slide 26Slide 27Slide 28Slide 29Slide 30Slide 31Slide 32 layer visibility=hide . layer visibility=hide layer visibility=hide Slide 1 Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[161]=new Array(0,1,"http://www.badgermetal.com/bmtcurves/1999-04grafx.htm","2009-07-17","24K","Metallife and Thermallife compression curves to extend die casting die life and improving performance of die casting dies and other molds. ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ",""," Metallife and Thermallife compression curves to extend die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Why we use Lambda? Combined MetaLL ifeŇ Curves showing T-41 through T-71 processes Click here - to view surface topography after MetaLL ifeŇ Compressive Stress Values as a function of Depth (1000psi = 1ksi = 6.9mpa = 6,895,000pa) Taken June 1997 values above 0 on the y axis show tensile stress - allows crackings values below 0 on the y axis show compressive stress - stops cracking VALUES FROM H-13 COUPON SAMPLES HARDENED TO 44-46Rc Click here to view separate curves The T-41H values for max depth are greater than the values for T-71 which exhibits less surface topography than T-41H The graph on this page is archived and cannot be changed Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[162]=new Array(0,1,"http://www.badgermetal.com/bmtcurves/lambdaxray.htm","2009-07-17","30K","Reasons why Lambda X-Ray Diffraction measurements is used by Badger Metal Tech ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite,xray, x-ray, lambda, proto ","Measuring the Metallife compression values using XRD X-Ray Diffraction methods by Lambda or Proto "," Reasons why Lambda X-Ray Diffraction measurements is used by Badger Metal Tech Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Why Badger uses Lambda X-Ray Diffraction measurements? Other companies that say they do the same process that Badger Metal does should be questioned regarding their proof of this claim. The only proven way to validate their declaration is by generating exacting curves using the below established procedures. Anything short of this is simply a hit and miss attempt at doing MetaLL ifeŇ and trying to accomplish what Badger Metal has developed and successfully been doing to all types of tool steels since 1983. MetaLL ifeŇ processing is monitored on a production basis by using Almen intensity strips. These strips are placed in strategic locations on the die or perishable tooling being processed. The Almen strip will bend when processed and by measuring the height of the center curvature, the approximate amount of induced surface compression can be determined. Various strip thickness are used dependent on the intensity of the process. i.e. For example, a T-21 process would use a thinner Almen strip than a more aggressive T-41H. While the Almen strip method is useful, it only provides a relative basis for measuring surface induced compression. Surface compression is important, but the depth and shape of the curve is what ultimately determines how well the process variables are being applied. The only accurate means for determining this residual stress distribution, is by measuring the surface and subsurface distribution of the compression. X-ray diffraction (XRD) is the most accurate and proven method of quantifying the subsurface r "); array_files[163]=new Array(0,1,"http://www.badgermetal.com/bmtcurves/lambda-ml-tl-curves.htm","2009-07-17","37K","Metallife and Thermallife compression curves for extending die casting die life and improving performance of die casting dies and other molds. ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, ","Individual graphs showing combinations of Metallife alone and combined with Thermallife with resultant compression curves "," Metallife and Thermallife compression curves for extending die casting die life and improving performance of die casting dies and other molds. Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Why we use Lambda? First curve shows our MetaLL ifeŇ T-41H process remaining curves show MetaLL ifeŇ + TherMaLLifeŇ combination processes. The TherMaLLifeŇ surface is in the mid 70Rc range. Compressive Stress Values as a function of Depth (1000psi = 1ksi = 6.9mpa = 6,895,000pa) Readings performed late Dec 2001 values above 0 on the y axis show tensile stress - allows crackings values below 0 on the y axis show compressive stress - stops cracking VALUES FROM H-13 COUPON SAMPLES HARDENED TO 44-46Rc Good surface compression (-120Ksi) and depth with topography Some surface compression (-60Ksi) but shallow depth no topography change. Both surface compression and depth values exhibit some loss when TherMaLLifeŇ is applied after MetaLL ifeŇ. Topography is still evident. High surface compression and depth when MetaLL ifeŇ is applied after TherMaLLifeŇ. No topography Highest surface compression and depth when MetaLL ifeŇ T-41H (high intensity) is applied over the TherMaLLifeŇ process slight topography. View Combined Graphs for the three Highest Compression Protection Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics co "); array_files[164]=new Array(0,1,"http://www.badgermetal.com/bmtcurves/fnc-curves.htm","2009-07-17","16K","Combining Metallife and Thermallife to maximize benefits of compressive stress ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite,xray, x-ray, lambda, proto ","X-ray diffraction curves showing Metallife and Metallife in Combination with Thermallife "," Combining Metallife and Thermallife to maximize benefits of compressive stress Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Why we use Lambda? Ferritic-Nitrocarburizing Curves & MetaLL ifeŇ + TherMaLLifeŇ combined Compressive Stress Values as a function of Depth Measured January 1999 To be updated 3rd quarter 2001 values above 0 on the y axis show tensile stress - destructive and initiates cracking values below 0 on the y axis show compressive stress - beneficial and stops cracking VALUES FROM H-13 COUPON SAMPLES HARDENED TO 44-46Rc Good surface compression -96.5 ksi Large knee to depth of approx .006 No visible topography of the surface No distortion, size, or tolerance changes Surface compression -192 ksi No knee to depth of approx .016 With visible topography (T-41H) to the surface "); array_files[165]=new Array(0,1,"http://www.badgermetal.com/bmtcurves/9909graf.htm","2009-07-17","32K","Compressive stress values for Metallife and Thermallife using test coupons ","heat checking, fatigue cracking, breakout from cavitation, Metallife, Thermallife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue, dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite,xray, x-ray, lambda, proto ","Differences using xray x-ray diffraction to measure compressive stress levels in die casting test coupons "," Compressive stress values for Metallife and Thermallife using test coupons Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Why we use Lambda? Current Curves for (FNC) TherMaLLifeŇ T-41H MetaLL ifeŇ before TherMaLLifeŇ T-41H MetaLL ifeŇ after TherMaLLifeŇ Compressive Stress Values as a function of Depth in KSI (1000psi = 1ksi = 6.9mpa = 6,895,000pa) Coupon Sample Types for 2001 in process Lab Dip Tank Testing to be Performed at Case Western Reserve values above 0 on the y axis show tensile stress - encourages cracking. values below 0 on the y axis show compressive stress - inhibits cracking VALUES FROM H-13 COUPON SAMPLES HARDENED TO 46-48Rc Graph A4 - X-ray diffraction curve for T-41H MetaLL ifeŇ The maximum compressive depth is -158 KSI(.006). Surface compression is -121 KSI. Maximum Depth .016 Graph A2 - X-ray diffraction curve for the TherMaLLifeŇ (FNC process). Maximum compression value is -145KSI at .002 in the surface diffused layer. Actual surface compression is -96 KSI. Maximum Depth .006 Graph A1 - X-ray diffraction curve for our COMBINATION of the two above processes. Note the high surface compression (-193 KSI) in the diffused layer. The knee of both curves has been slightly flattened, however, the magnitude of -96 KSI and depth (.016) offers excellent protection against thermal heat checking. If desired, we can combine the TherMaLLifeŇ process for die casting dies with MetaLL ifeŇ by first closing small sampling cracks on NEW tools and minor heat checks on USED tools. Then following this with our TherMaLLifeŇ diffusion treatment. Tooling may be processed with FNC TherMaLLifeŇ as a stand alone process on thermoset plastic molds when topography is a problem. TherMaLLifeŇ is not a line of site process as are some coatings or plating processes so you are assured of compl "); array_files[166]=new Array(0,1,"http://www.badgermetal.com/nadca-supplier-excellence-2008.htm","2009-07-17","21K","Edward A Kruszynski Supplier Award 2008 ","",""," Edward A Kruszynski Supplier Award 2008 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Edward A. Kruszynski - Supplier Excellence Award - May 2008 Atlanta, GA Casting ExpoThis award recognizes a supplier to the die casting industry that has demonstrated a long-standing record of NADCA membership, participation in and furthering of NADCAs education efforts, longevity as an exhibitor in the International Congress & Exposition and Die Casting Engineer advertiser, and participation in NADCA committees and boards. Originally introduced as the Achievement Award in 1960, it was renamed the Edward A. Kruszynski Achievement Award in 1987 and the Edward A. Kruszynski Supplier Excellence Award in 1991. There have only been 25 recipients of this award since it was started in 1960. Jerald (Jerry) V. Skoff - President and Founder Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[167]=new Array(0,1,"http://www.badgermetal.com/field-tl.htm","2009-07-17","61K","Testimonials and Letters for Thermallife ","",""," Testimonials and Letters for Thermallife Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com : Testimonies Photos of tooling Test Result Comments (Our customer comments are numerically coded to protect our clients security and wishes) We update this page as more results are received. Resolved and Reduced Soldering of Die Cast Tooling Improved Fatigue Resistance for Die Cast and Draw Tooling Reduction in gate erosion in Die Cast Tooling Reduction of Galling for Draw Dies Reduced Wear and Improved Fatigue Strength - Hot Forging Reduced Soldering #790 - IA - Pleased with TherMaLLifeŇ performance to date on all tooling processed. Said its working good. Also advised business is good. #955 - AR - In 2007 January, we lost our source for SolveniteŇ. Thermallife has proved to be an ideal alternative solution which is also less expensive than our previous lost source. #955 - CO - Core pins would solder after only 500 shots. Production costs were sky-rocketing due to downtime. After TherMaLLifeŇ was able to run 5000 parts and finish the run without a single downtime for the previous problem. #007 - WI - Once used a process similar to this until the local plant closed. Am glad to see that the technology has improved so that can provide the consistent results that we could not obtain from other processes. Use it on cores and slides that have a tendency to solder and/or gall. May try on some problem die casting inserts in the near future. #054 - IL - Have been using TherMaLLifeŇ since its introduction in July 2001. Applications to cores have reduced or eliminated previous soldering problems. Works equally well on problem molds that have a tendency to solder. Have tri "); array_files[168]=new Array(0,1,"http://www.badgermetal.com/ml-dfs/crack-punch-dfs.htm","2009-07-17","23K","Metallife is not a coating or plating that prevents die cracking of drawing forming blanking tooling ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ","Prevents fatigue cracking of blanking and piercing punches by increasing the fatigue strength "," Metallife is not a coating or plating that prevents die cracking of drawing forming blanking tooling Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Simulation comparing treated and untreated punch tools. The below illustrations shows blanking punch benefits when using MetaLL ifeŇ Punch wiped and no compression before MetaLL ifeŇ. Lube retention and compression after MetaLL ifeŇ application Return to Stops Fatigue Page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[169]=new Array(0,1,"http://www.badgermetal.com/ml-dfs/signif-dfs.htm","2009-07-17","21K","Metallife is not a coating or plating significantly extends die life of drawing forming blanking tooling ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ","Extend the die life of drawing forming and stamping dies "," Metallife is not a coating or plating significantly extends die life of drawing forming blanking tooling Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Significantly Extends Die Life Both our Field testing of Draw Forming and Stamping confirm that by increasing the fatigue strength of any cold work tool steel, that the life of a die is improved by a factor of anywhere from 2-10 times depending on the application. One of the most difficult tests to pass is Case Westerns Dip Tank test that they only run on Hot Work steels (H-13). This steel, which is used in die casting, has tendency to build up stresses rapidly due to the extremes in operating temperature seen during production of castings. Once the yield strength of the steel is exceeded, the die surface starts to exhibit cracking. This cracking, commonly known in the industry as heat checking, if unattended, will lead to a catastrophic failure of the tool. Draw Forming & Stamping tooling, with the exception of Hot Forging dies, do not see this extreme use yet still can significantly show large life cycle improvements by the MetaLL ifeŇ process. Numerous field tests on both draw forming and blanking tooling confirm this fact. Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[170]=new Array(0,1,"http://www.badgermetal.com/ml-dfs/applies-dfs.htm","2009-07-17","24K","Metallife is not a coating or plating that improves the life of drawing forming blanking tooling ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ","Not a coating or plating that applies to hot and cold work steels used for drawing forming blanking dies "," Metallife is not a coating or plating that improves the life of drawing forming blanking tooling Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Applies to Hot & Cold Work Steels MetaLL ifeŇ is not a coating or plating but a molecular stress change to the surface of the steel. Penetration depth is .010 to .018 of an inch subsurface. Since it is performed at room ambient conditions with no heat involved, the initial heat treat specifications cannot be compromised or changed. There is also no danger of distortion, size or tolerance changes. Applications include all type of hot & cold work steels including: Hot Work (H-13 , P-20, and Maraging) and Cold Work (D2, A2, O2 and others) steels. The process may be applied as often as required or desired with no build up on the tool since only the base metal surface is affected with nothing being deposited to the dies surface. The below macro photo shows a treated and untreated specimen of H-13 steel. Note how well the surface inclusions and polish marks have been removed by the MetaLL ifeŇ process. The evident topography is inversely proportional to the hardness of the material. H-13 will show more topography (which is desired in die casting) because of its relative softness (44-48Rc) as compared to Cold Work steels hardness of 58-62Rc. For Cold Work steels the topography is not readily evident to the naked eye but can be seen if the surface is magnified (10x lupe). MetaLL ifeŇ area shows uniform topography and no inclusions. Unprocessed half with inclusions and polish marks over the entire surface Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996 "); array_files[171]=new Array(0,1,"http://www.badgermetal.com/ml-dfs/faqml-dfs.htm","2009-07-17","45K","Metallife is provides excellent protection for the life of drawing forming blanking tooling ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ","Frequently asked questions (FAQ) about drawing forming blanking dies and extending the life of dies "," Metallife is provides excellent protection for the life of drawing forming blanking tooling Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Frequently Asked Questions Draw Forming / Blanking Compressive Stress benefits of applying MetaLL ifeŇ after TherMaLLifeŇ to NEW tooling validated by Lambda labs. click on photo Here are some facts regarding MetaLL ifeŇ that should answer common questions relating to our compression surface treatment. MetaLL ifeŇ is unique in that it is the only surface treatment capable that is performed at room ambient conditions so there is not compromise of the initial heat treatment. It is available since 1983, only from Badger Metal Tech, Inc. in Menomonee Falls, Wisconsin. Our certificate of compliance assures your satisfaction. Make sure you request this when placing your order. Coatings and diffusion processes Applying to New tooling Topography v/s drag Thermal transfer coefficient Stress relieving methods Application to welds Previously hardened surfaces Tooling Dimension and Tolerance Changes Questions/Topic Response Coatings and Diffusion Do I need to do anything else to my tooling? What about coatings, platings, and diffusion processes? Is it important to prepare the substrate before a coating is applied. MetaLL ifeŇ, by itself, provides excellent protection against fatigue, galling, and pickup. It also improves metal flow characteristics. If so desired, MetaLL ifeŇ can be subsequently coated or treated with other processes including our TherMaLLifeŇ process. We caution against the use of any subsequent treatment that involves the use of an extended high heat (1800-1900 degrees F) condition. X-ray diffraction tests show no degradation of the compressive stress benefits when Balzers coatings such as the popular Titanium Aluminum Nitride (TiAlN - "); array_files[172]=new Array(0,1,"http://www.badgermetal.com/lambda-coupons-dc.htm","2009-07-17","42K","Coupons used for plotting compression curves - Die Casting ","",""," Coupons used for plotting compression curves - Die Casting Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Print this Page Coupons that were used for plotting 2002 compression curves. Why do we use Lambda? Curves and Graphs Please scroll this entire page These results validate compressive benefits after thermal diffusion Click here Die Photos with Graph of Coupon A B click on photo above or letters for more info Graph of Coupon C D click on photo above or letters for more info The coupons measure approximately .75 x .25 and are 3 long. Center sections were measured, plotted, then electro-polished to remove material. X-ray diffraction was again used to measure stress and the process repeated until the value of KSI crossed the zero y axis. From these plotted points curves are drawn. H-13 Premium Grade Oil Quenched 46-48Rc Milled Finish Polished +1000 degrees F The small square in the center of each coupon is the area were successive compressive residual stress readings were done by electro-polishing the surface. This method of polishing does not disturb the existing value of stress. The microstructure of a ferritic nitrocarburized H-13 surface shows an epsilon compound layer that is .0002 to .0008 in depth followed by the diffused carbon/nitrogen layer ranging in depth from .004 to .008 (dependent on processing criteria) which gradually dissipates. If the diffusion is allowed to become too thick, spalling can result. We therefore have developed special recipes for all types of hot work steels that do not result in what you view here. If we were to do a maximum of our T-41H MetaLL ifeŇ process over the TL08 TherMaLLifeŇ recipe, you would see what we ha "); array_files[173]=new Array(0,1,"http://www.badgermetal.com/index.htm","2009-07-17","25K","Prevent and fix die casting die failure modes heat check breakout soldering of aluminum laminar fill ","heat checking, fatigue cracking,breakout from cavitation, Metallife, Thermallife, Metalife, Thermalife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue,dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, reduce die casting scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, Metal life, Metal life process, metallife process, die casting surface treatments, die surface treatment, die surface engineering, metal life surface treatment, die lube, die lubricant, die casting lubricant, die lubricity, lubricity, shot peening, metallife peening, die shot peening, peening, laser peening, precision peening, precision peening process, precision shot peening, precision shot peening process, residual stress, controlled residual stress, compressive stress texturing, controlling residual stress, reducing residual stress, residual compressive stress, compressive stress, surface compression, weld peening, weld shot peening, cycle failure, surface coating, die casting coating, coating process, die surface coating, mechanical coating, mechanical coating process, casting porosity, breakout, die breakout, diamond polishing, diamond polish, flash, flash reduction, reduced flashing, flashing, gross cracking, NADCA, North American Die Casting Association, shot blasting, abrasive blasting, blasting, stress relief ","Die casting die failure modes Die surface treatment coatings for die casting dies, plastic injection molds using Metallife and Thermallife to prevent heat checking, cavitation breakout and pitting, soldering, porosity along with reducing down time from these failures. "," Prevent and fix die casting die failure modes heat check breakout soldering of aluminum laminar fill Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Die and Mold Maintenance Specialists Over 25 years of experience in die materials, metallurgy, and manufacturing make Badger Metal Tech the reliable resource for die and mold maintenance. North American Manufacturing relies on Badger Metal Tech to provide comprehensive Preventative Maintenance Programs for die cast dies and plastic injection molds.Maximizing tooling life and enhancing performance are one of the keys to controlling costs and saving energy. Using the latest in application technology, MetaLL ifeŇ and TherMaLLifeŇ are two cost effective surface treatments used extensively in the tooling industry. Mission Statement Badger Metal Tech is committed to providing, in a timely manner, proprietary quality unique surface treatments that improve the performance and extend the life of die casting tools as well as enhancing the performance of all other types of perishable tooling, including drawing/ forming/ stamping dies, and plastic molds. We work closely as free consultants having over 25 years of direct experience helping customers find ways to reduce tooling costs while creating higher quality products for OEM’s. Die Casting Die Failure Modes Aluminum, Magnesium, Zinc, Brass, Bronze - Cast Metals Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and T "); array_files[174]=new Array(0,1,"http://www.badgermetal.com/","2009-07-17","25K","Prevent and fix die casting die failure modes heat check breakout soldering of aluminum laminar fill ","heat checking, fatigue cracking,breakout from cavitation, Metallife, Thermallife, Metalife, Thermalife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue,dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, reduce die casting scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, Metal life, Metal life process, metallife process, die casting surface treatments, die surface treatment, die surface engineering, metal life surface treatment, die lube, die lubricant, die casting lubricant, die lubricity, lubricity, shot peening, metallife peening, die shot peening, peening, laser peening, precision peening, precision peening process, precision shot peening, precision shot peening process, residual stress, controlled residual stress, compressive stress texturing, controlling residual stress, reducing residual stress, residual compressive stress, compressive stress, surface compression, weld peening, weld shot peening, cycle failure, surface coating, die casting coating, coating process, die surface coating, mechanical coating, mechanical coating process, casting porosity, breakout, die breakout, diamond polishing, diamond polish, flash, flash reduction, reduced flashing, flashing, gross cracking, NADCA, North American Die Casting Association, shot blasting, abrasive blasting, blasting, stress relief ","Die casting die failure modes Die surface treatment coatings for die casting dies, plastic injection molds using Metallife and Thermallife to prevent heat checking, cavitation breakout and pitting, soldering, porosity along with reducing down time from these failures. "," Prevent and fix die casting die failure modes heat check breakout soldering of aluminum laminar fill Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Die and Mold Maintenance Specialists Over 25 years of experience in die materials, metallurgy, and manufacturing make Badger Metal Tech the reliable resource for die and mold maintenance. North American Manufacturing relies on Badger Metal Tech to provide comprehensive Preventative Maintenance Programs for die cast dies and plastic injection molds.Maximizing tooling life and enhancing performance are one of the keys to controlling costs and saving energy. Using the latest in application technology, MetaLL ifeŇ and TherMaLLifeŇ are two cost effective surface treatments used extensively in the tooling industry. Mission Statement Badger Metal Tech is committed to providing, in a timely manner, proprietary quality unique surface treatments that improve the performance and extend the life of die casting tools as well as enhancing the performance of all other types of perishable tooling, including drawing/ forming/ stamping dies, and plastic molds. We work closely as free consultants having over 25 years of direct experience helping customers find ways to reduce tooling costs while creating higher quality products for OEM’s. Die Casting Die Failure Modes Aluminum, Magnesium, Zinc, Brass, Bronze - Cast Metals Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and T "); array_files[175]=new Array(0,1,"http://www.badgermetal.com/ml-dfs/shows_dfs.htm","2009-07-17","12K","Metallife is not a coating or plating that improves bottom line profits of drawing forming blanking tooling ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ","Reducing costs of tooling by coating to improve the life and performance of drawing forming blanking dies "," Metallife is not a coating or plating that improves bottom line profits of drawing forming blanking tooling Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Shows Bottom Line Profits With the state of our manufacturing today and the unfair competition that China and the recently imposed steel tariffs are causing, it is of utmost importance that all manufacturers optimize their profits. One costly area that is often overlooked is the tooling and tooling maintenance. How much downtime is the tool seeing because of problems with galling, pickup, and/or fatigue? Many times these downtime losses do not show up as a figure on the bottom line, however, they do show themselves in overall profit reports. By being proactive in this area, the draw forming / blanking industry can pay attention to these profit robbing trends. Imagine being able to run a tool for extended periods without any pickup or galling. Think of punches that usually fatigue now no longer failing on the sharp edges. Isnt it time to do something about this problem? Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[176]=new Array(0,1,"http://www.badgermetal.com/ml-dfs/elim-dfs.htm","2009-07-17","22K","Metallife is not a coating or plating that eliminates EDM stress of drawing forming blanking tooling ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ","Eliminate stresses from EDM that can shorten the life of tooling "," Metallife is not a coating or plating that eliminates EDM stress of drawing forming blanking tooling Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Eliminates EDM Stresses Electrical Discharge Machining while providing a relatively inexpensive means for producing die casting die inserts, unfortunately, at the same time, sets up some very high and detrimental EDM surfaces stresses that if not properly tended to will actually accelerate thermal stress cracking. Since metal is removed by a series of electrical spark discharges, the steel in the contact area melts or vaporizes then solidifies on the surface of the cavity. Each spark erodes a tiny bit of metal, leaving a small crater in the surface of the tool. This leaves the surface in a high residual stress condition which can lead to early heat checking and possible gross cracking. The top most or recast layer is a brittle, non-etch white layer containing cracks. This is the material that has melted and rapidly solidified and is not flushed away by the die electric fluid. This layer is densely infiltrated with carbon and has a distinct separate structure to that of the parent metal. Below this layer is the heat affected zone that has been structurally altered by the heat produced during EDM which reaches the austenizing temperature of the steel. This zone may contain re-hardened or hard, brittle untempered martensite which is formed during the rapid cooling from this temperature. This can be expected to increase crack susceptibility since such a microstructure stores considerable strain energy that decomposes with heat. After mandatory removal by polishing of the top white cast layer it is important "); array_files[177]=new Array(0,1,"http://www.badgermetal.com/ml-dfs/increase-dfs.htm","2009-07-17","21K","Metallife is not a coating or plating that increases die lubricity of drawing forming blanking tooling ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ","Topography surface texturing that increases die lubricity and adhesion of die lubricant for drawing forming dies "," Metallife is not a coating or plating that increases die lubricity of drawing forming blanking tooling Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Increases Die Lubricity The topography of the MetaLL ifeŇ creates micro pockets for trapping and holding lubricant on the draw form or blanking die and punch surface of the tool. The process also adds a lubricity factor to the dies surface to make it more slippery. This along with the increased surface area caused by the non-linear surface provides a more effective foundation for the applied lubricant retention and piece part release. Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[178]=new Array(0,1,"http://www.badgermetal.com/ml-dfs/decreses-gall-dfs.htm","2009-07-17","26K","Metallife is not a coating or plating that reduces galling and pickup of drawing forming blanking tooling ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ","Decreases galling and pickup of draw dies with using a coating to increase the life of tooling "," Metallife is not a coating or plating that reduces galling and pickup of drawing forming blanking tooling Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Decreases Galling/Pickup of Drawing Dies Drawing/Forming Dies Loss of the tools lubrication barrier between the die and worked part causes problems similar to those experienced in die casting operations. The metal from the worked part galls and adheres to the surface of the draw or forming tool. The carbon steel electrons and worked part metal content have a natural affinity for each other. This bond is usually inter-metallic in nature and can only be removed by re-polishing the tool. In doing so, part of the die steel is also removed in the process. The micro topography compressive stress created during the MetaLL ifeŇ process is able to retain more lubricant than a polished or flat surface and thus maintains the needed barrier to prevent this covalent electron bonding from occurring between the metals. The uniform micro-topography of the MetaLL ifeŇ also affords more surface area for the lube to adhere to than a flat one and creates greater heat dissipation at the dies surface without causing excessive lube build-up on the tool. This increased heat dissipation allows the tool to run cooler thus extending the tools life while increasing lube retention ability. The use of coatings in conjunction with MetaLL ifeŇ is also assisting in solving this problem, however, the substrate preparation is critical to preventing failure of the coating. Since most PVD (low temperature) coatings are very thin and layed down in a crystal matrix fashion, they must have a good working base prior to their application. "); array_files[179]=new Array(0,1,"http://www.badgermetal.com/ml-dfs/enhance-dfs.htm","2009-07-17","22K","Metallife is not a coating or plating that enhances the appearance of parts made from drawing forming blanking tooling ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ","Metallife will enhance the drawing or forming part appearance by improving the flow the the metal "," Metallife is not a coating or plating that enhances the appearance of parts made from drawing forming blanking tooling Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Enhances Appearance of parts It is not normally recognized in the drawing / forming industry that topography of a tools surface improves the flow of metal. Tool makers like to polish to a mirror finish. This is like waxing the hood of your car and then pouring water on it. As we all know it beads up and quickly runs off. Topography goes directly against what has been taught for years in the draw tool industry. A tool after MetaLL ifeŇ processing has micro topography (visible only under high magnification powers) surface which evidences as a brushed metal finish to the naked eye. Because of this topography, the surface of the tool has more surface area for lube adhesion along with microscopic pockets that trap and hold the lubricant. This permits a cleaner draw cycle. Produced parts have a better appearance since it is less likely that tearing or galling of the part can occur. Piece part on left has galling and pickup that is evident due to the loss of lubricant during the forming process. Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[180]=new Array(0,1,"http://www.badgermetal.com/ml-dfs/verifies-dfs.htm","2009-07-17","21K","Metallife is not a coating or plating that verifys surface hardness integrity of drawing forming blanking tooling ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ","Badger Metal Tech uses instruments and processes that will verify die hardness "," Metallife is not a coating or plating that verifys surface hardness integrity of drawing forming blanking tooling Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Verifies Surface Hardness / Integrity Dies that are inherited from another drawing / forming / stamping company are sometimes very old, and have no history to show prior maintenance that was done to the tool. MetaLL ifeŇ verifies the surface hardness of these dies and then gives visual evidence after processing that verifies where and if the dies has been nitrided, welded, coated, or quenched improperly during heat treat. In addition each insert over 50lbs. is surface hardness checked prior to processing, using an EquoTip velocity hardness instrument. Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[181]=new Array(0,1,"http://www.badgermetal.com/coat-hard-large.htm","2009-07-17","19K","Large view of coating hardness Graph ","",""," Large view of coating hardness Graph Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[182]=new Array(0,1,"http://www.badgermetal.com/ml-dfs/stops-dfs.htm","2009-07-17","24K","Metallife is not a coating or plating stops fatigue cracking of drawing forming blanking tooling ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ","Metallife stops the fatigue cracking of drawing/forming/stamping dies "," Metallife is not a coating or plating stops fatigue cracking of drawing forming blanking tooling Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Stops Fatigue Cracking Stress Cycle Illustration of Before and After on NEW tooling. MetaLL ifeŇ protects drawing / forming / stamping tools from initial or subsequent fatigue stress cracking by replacing detrimental residual tensile stresses with an encapsulating subsurface region of compressive stress. For comparative compressions curves, see sample X-ray diffraction Lambda Curves. By having a compressive force in place, the initiation and propagation of fatigue cracks is prevented. Cracks cannot propagate into or through this layer of compressive stress unless the increased effective yield fatigue strength of the steel is exceeded which MetaLL ifeŇ increases by 30-40%. MetaLL ifeŇ is best applied to NEW tools, however, USED tools can also be processed providing they are in a usable ready for production condition. On softer steel hardness materials, such as seen in Hot Work Steels, it is possible to close smaller existing cracks. The range of hardness for D2, A2, and M steels prevents this from occurring. As most metallurgists know, a crack can not propagate into or through a layer of compression unless the fatigue yield strength is exceeded. See photos below and click here to see illustration of stress cycle for unprocessed and processed punch. Before - polish marks and inclusions that cause initiation of cracking. After - MetaLL ifeŇ crack initiators are not longer present. Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal "); array_files[183]=new Array(0,1,"http://www.badgermetal.com/pct-broch-1.htm","2009-07-17","26K","Perishable Cutting Tool brochure-page3 ","",""," Perishable Cutting Tool brochure-page3 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com click on right arrow start tour and/or pricing for Taps Hobs - pricesheet Drills Endmills Hog Mills Chasers Form Tools Broaches Slitting Saws Spade Drills Drawing Dies Stamping Dies Milling Cutters Punching Dies Key Seat Cutters Die Casting Dies Cold Forming Dies Spot Welding Tips Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[184]=new Array(0,1,"http://www.badgermetal.com/ml-dfs/metalife-dfs.htm","2009-07-17","21K","Metallife is not a coating or plating that extends die life of drawing forming blanking tooling ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ","Summary of benefits for Metallife when applied to drawing forming blanking dies "," Metallife is not a coating or plating that extends die life of drawing forming blanking tooling Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files tops fatigue failures of blanking dies pplies to all Cold Work Steels erifies Surface Hardness nhanced appearance of parts ignificantly Extends Die Life ecreases Galling for draw dies ncreases Surface Lubricity liminates EDM Stresses hows bottom line improvements The future in Laser Technology Other Benefits: Reduced tearing of drawing parts Ideal substrate preparation for coatings or low temp diffusion processes Can be welded and or machined without first removing Micro-pockets on the surface trap lubricant Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[185]=new Array(0,1,"http://www.badgermetal.com/tl-dfs/faqtl-dfs.htm","2009-07-17","65K","Thermallife FAQs ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ",""," Thermallife FAQs Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Draw Forming / Blanking Frequently Asked Questions Compressive Stress benefits of applying MetaLL ifeŇ after TherMaLLifeŇ to NEW tooling validated by Lambda labs. click on photo return Here are some facts regarding TherMaLLifeŇ that should answer common questions regarding our diffusion treatment. Those that have used our NEW diffusion process are seeing measurable cost saving improvements in tooling performance. What makes TherMaLLifeŇ unique is that it is performed in an automated, controlled atmosphere. This allows us to automatically control temperatures, gas velocity, and pressures to assure maximum repeatability. TherMaLLifeŇ, available since July 2001, is only available from Badger Metal Tech, Inc. in Menomonee Falls, Wisconsin. Our certificate of compliance assures your satisfaction. Make sure you request this when placing your order especially if you have ISO or QS requirements. Welding Perform on USED tooling Size change or distortion Differences in TL processes Criteria for correct TL process H-13 v/s Anviloy Flaking, chipping, peeling Hot Work Steel Concerns? What about lubricity? Dievar considerations Applying over PVD coatings Applying PVD coatings over Topic Response Can you weld over the process? back to index You may have heard that welding over a nitrided surface is difficult. This is because of the sputtering from the diffused nitrogen in the steel. When heated the nitrogen expands and pops. Nitrocarburzing also has some nitrogen in the surface so sometimes, it can sputter, but welding can be done without significant problems. Can it be done to used tooling? back to "); array_files[186]=new Array(0,1,"http://www.badgermetal.com/dc-dfs-tl.htm","2009-07-17","28K","Choose Thermallife for Die Casting or Drawing, Forming, Blanking ","",""," Choose Thermallife for Die Casting or Drawing, Forming, Blanking Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Die Casting Drawing Forming Blanking + Die Casting Metal Forming Copyright © 2003 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[187]=new Array(0,1,"http://www.badgermetal.com/tl-dfs/thermallife-dfs.htm","2009-07-17","83K","Thermallife Home - Drawing Forming Blanking ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ",""," Thermallife Home - Drawing Forming Blanking Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Draw Form / Blanking Electronic Newsletters MetaLL ifeŇ or TherMaLLifeŇ click on above photo for advanced information click on award for more info Supplier Excellence May 2008 MetaLLifeŇ TherMaLLifeŇ Tooling Benefits TherMaLL ifeŇ An exclusive Badger Metal Tech surface treatment that offers the benefits of ferritic nitrocarburizing performed in a fully controlled atmosphere. TherMaLLifeŇ is a nitrocarburizing treatment. Since it is done at a comparatively low temperature and is a diffusion process, distortion, size, and tolerance changes of the tool are not a problem. This process has application benefits not only for die casting dies but also for other forms of perishable tooling including: H-13 Die Casting Dies H-13 Thermoset Plastic Molds Permanent Molds Drawing Dies Stamping Dies Blanking Dies Forming Dies Forging Dies With the addition of the TherMaLLifeŇ we have expanded our capabilities to other areas of tooling and can now offer benefits such as: Increased wear resistance Anti-galling properties Improved fatigue strength High surface hardness Corrosion resistance (except in the case of stainless steels) Resistance to the softening effect of heat Since 1983, MetaLL ifeŇ has become the standard in the Die Casting Industry for compressive protection against heat checking for NEW die cast tooling and its ability to close and retard additional thermal cracking on USED tooling. The MetaLL ifeŇ topography created in the case of H-13 or other hot work metal steels, aids in enhancing the surfaces lubricity as well as providing a means to trap die lubricant. Th "); array_files[188]=new Array(0,1,"http://www.badgermetal.com/tl-dfs/otherphotos-dfs.htm","2009-07-17","20K","Photos of Drawing Forming Blanking Dies ","drawing, forming, blanking, fatigue, blanking dies, forming dies, drawing dies, Metallife, Thermallife, coating drawing dies, coating forming dies, coating blanking dies, blanking punches, coating blanking punches, galling, stop galling, pickup on draw dies, treating drawing dies, balzers, ion bond, phygen, philo, coatings, platings, diffusion coatings, ",""," Photos of Drawing Forming Blanking Dies Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com return to previous page Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[189]=new Array(0,1,"http://www.badgermetal.com/tl-steel-id-form.htm","2009-07-17","23K","Thermallife Steel Identification Form - New 2005 ","",""," Thermallife Steel Identification Form - New 2005 Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com TherMaLLifeŇ involves the application of heat. Since some tool materials will diffuse and create a compound layer at substantially different rates, it is critical to know steel types. This is true especially in the case of Uddeholms DieVarŇ or Schmolz+Bickenbach 2367 hot work tool steel as well as other specialty steels. To assist you in communicating this to us, we have developed a simple form that will assure that the correct recipe is applied to your tooling Click on the green button below to open, save, or download our form in pdf format. This form must be completed and accompany your parts or can be emailed or faxd to us. This assures that the tooling is properly processed. click on the button and print form in landscape mode Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[190]=new Array(0,1,"http://www.badgermetal.com/gallery-overview.htm","2009-07-17","21K","Gallery of Photos of dies that have been processed with Metallife or Thermallife ","heat checking, fatigue cracking,breakout from cavitation, Metallife, Thermallife, Metalife, Thermalife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue,dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, reduce die casting scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, Metal life, Metal life process, metallife process, die casting surface treatments, die surface treatment, die surface engineering, metal life surface treatment, die lube, die lubricant, die casting lubricant, die lubricity, lubricity, shot peening, metallife peening, die shot peening, peening, laser peening, precision peening, precision peening process, precision shot peening, precision shot peening process, residual stress, controlled residual stress, compressive stress texturing, controlling residual stress, reducing residual stress, residual compressive stress, compressive stress, surface compression, weld peening, weld shot peening, cycle failure, surface coating, die casting coating, coating process, die surface coating, mechanical coating, mechanical coating process, casting porosity, breakout, die breakout, diamond polishing, diamond polish, flash, flash reduction, reduced flashing, flashing, gross cracking, NADCA, North American Die Casting Association, shot blasting, abrasive blasting, blasting, stress relief, ion bond diffusions, solder of die casting dies, blistering, blast sand blast cleaning, ","thumbnail and larger photos of dies processed with Metallife or Thermallife along with some before and after photos of these dies "," Gallery of Photos of dies that have been processed with Metallife or Thermallife Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[191]=new Array(0,1,"http://www.badgermetal.com/main-dc.htm","2009-07-17","42K","Badger Metal Tech - Home Die Casting ","=metalife, metalife, metalife, metalife, metalife, metallife, metallife, metallife, thermallife, thermallife, thermallife, thermalife, thermalife, theremalife, metalife compressive stress topography, compressive stress, diecast, die casting, stamping dies, stamping tools, stamping tooling, drawing dies, drawing tooling, forming dies, forming tooling, extruding dies, extruding tooling, tool protection, tool protection, tool protection, lubricity, lubricity, lubricity, tool life, tool life, edm, electrical discharge machining, wire edm, thermal, thermal stress, heatchecking, heat checking, heat check, stress temper, stress relieve, washout, erosion, thermal shock, tool life, soldering, sticking, metallife, metallife, movies, metal life, meta life, metallife, micro peening, peening, diffusion process, ferritic nitro-carburizing, diffusion, ferritic nitrocarburizing, nitriding, nitriding, nitriding, tufftride, tufftride ","=Metalife and Thermallife are not coatings or plating processes but proprietary compressive and fnc surface treatments for New and Used die casting and H-13 plastic tooling that closes existing heatcheck cracks in die casting dies, along with retarding the development of new cracks. Metalife also reduces the interactive soldering effects of aluminum metal to hot work steel dies. Stamping-Drawing-Forming tools also benefit by reducing galling and pickup along with preventing the edge breakdown of blanking tooling "," Badger Metal Tech - Home Die Casting Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files The future in Laser Technology Find answers to your questions MetaLL ifeŇ TherMaLLifeŇ Mechanical Compressive Benefits Click here or Photo Die Casting Serving the Tool & Die Industry since 1983 N60 W15088 Bobolink Ave. Menomonee Falls, WI 53051 Thermo-chemical Diffusion Benefits Click here or photo coating MetaLL ifeŇ or TherMaLLifeŇ? MetaLLifeŇ TherMaLLifeŇ Other beneficial Information Proquis and AllClear Business Management Software Measurement Conversion Program (Free) - Screenview Removing Die Cast Intermetallic Soldering with Ultrasonics Residual Stress Analysis Build your FlowCharts Analyse Data in Minutes vs Hours Some pages on our site were last updated July 07, 2009. If a page have been revised, it will be so indicated at the bottom. Copyright © 2003-2006 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. The Badger Metal Tech and MetaLL ifeŇ and TherMaLLifeŇ registered trademarks of Badger Metal Tech, Inc. as well as the complete intellectual property and graphics as so here published. Should you find problems with this site or broken links, please contact our webmaster webmaster@badgermetal.com Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[192]=new Array(0,1,"http://www.badgermetal.com/about-us.htm","2009-07-17","21K","About Badger Metal Tech and it history with reducing residual stress ","heat checking, fatigue cracking,breakout from cavitation, Metallife, Thermallife, Metalife, Thermalife, die life, tool life, porosity, lamination, laminar fill, pitting, coatings, die surface treatments, die casting, die cast die welding, thermal fatigue, premature tool failure, edm effect, gate erosion, washout, peening, shot peening, fnc, ferritic nitrocarburizing, nitrocarburizing, nitro-carburizing, dynablue,dyna-blue, dyna blue, case hardening, nitriding, die substrate, die soldering, reduce scrap, reduce die casting scrap rate reduction, texturing, die surface texturing, casting texturing, compressive stress, stress relieving, stress temper, lubricity, die lube retention, die spray, improved flow, reduce flow lines, gate and runner systems, gate texturing, rocklinzing, balzers, phygen, colorado school of mines, philo, salt bath, melonite, Metal life, Metal life process, metallife process, die casting surface treatments, die surface treatment, die surface engineering, metal life surface treatment, die lube, die lubricant, die casting lubricant, die lubricity, lubricity, shot peening, metallife peening, die shot peening, peening, laser peening, precision peening, precision peening process, precision shot peening, precision shot peening process, residual stress, controlled residual stress, compressive stress texturing, controlling residual stress, reducing residual stress, residual compressive stress, compressive stress, surface compression, weld peening, weld shot peening, cycle failure, surface coating, die casting coating, coating process, die surface coating, mechanical coating, mechanical coating process, casting porosity, breakout, die breakout, diamond polishing, diamond polish, flash, flash reduction, reduced flashing, flashing, gross cracking, NADCA, North American Die Casting Association, shot blasting, abrasive blasting, blasting, stress relief ","precision shot peening process history of metallife peening process "," About Badger Metal Tech and it history with reducing residual stress Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[193]=new Array(0,1,"http://www.badgermetal.com/stuff/Convert/convert.htm","2009-07-17","21K","Free Conversion Program - zipped ","",""," Free Conversion Program - zipped Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com All the files Web pages Text files Adobe PDF MS Word MS Excel MS PowerPoint RTF files Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Javascript DHTML Drop Down Menu Powered by dhtml-menu-builder.com Screenshot of Convert Program download Page was last modified Sunday, July 12, 2009 home about us services gallery glossary contact us Copyright © 1996-2009 Badger Metal Tech, Inc. All Rights Reserved. Reproduction in whole or in part in any form or medium without express written permission of Badger Metal Tech is Prohibited. MetaLL ifeŇ and TherMaLLifeŇ are registered with the US patent and trademark office. Intellectual property and graphics contained herein are the sole property of Badger Metal Tech, Inc. "); array_files[194]=new Array(0,1,"http://www.badgermetal.com/MKC/index.htm","2009-07-12","2K","Requests ","",""," Requests To see a sample of our 24/7 web update, login with your user ID and Password. test ID = bmt2008 password = custsyn We would use this to securely track die usage and proactive die maintenance Login Area UserID: Password: "); array_files[195]=new Array(0,1,"http://www.badgermetal.com/slideshows/success-stories-slides/Congress2009Success-Stories-18Slides.htm","2009-07-12","2K","4 Field Success Stories using Metallife & Thermallife ","","3/22/2009: 4 Success Stories T09-074 "," 4 Field Success Stories using Metallife & Thermallife Steve Robison P Point Template Jerry Skoff 149 1737 1999-06-23T19:16:47Z 2009-03-22T23:18:48Z 401 On-screen Show American Foundrymens Soceity 99780 111 18 11.9999 80 This presentation contains content that your browser may not be able to show properly. This presentation was optimized for more recent versions of Microsoft Internet Explorer. If you would like to proceed anyway, click here. "); array_files[196]=new Array(0,1,"http://www.badgermetal.com/slideshows/residual-stress-slides/2003-03-residual-stress-15slides.htm","2009-07-12","3K","Residual Stress Baseline Study ","","=3/22/2009: Residual Stress Build Up Baseline NADCA Test "," Residual Stress Baseline Study Jerry Skoff C:Program FilesMicrosoft OfficeTemplatesPresentation DesignsRadar.pot Jerry Skoff 576 3787 2000-04-22T18:18:49Z 2000-12-18T15:31:49Z 2009-03-22T23:34:02Z 439 On-screen Show Badger Metal 14234774 112 15 3 11.9999 80 This presentation contains content that your browser may not be able to show properly. This presentation was optimized for more recent versions of Microsoft Internet Explorer. If you would like to proceed anyway, click here. "); array_files[197]=new Array(0,1,"http://www.badgermetal.com/slideshows/gross-cracking-slides/gross-cracking.htm","2009-07-12","2K","Modes and Causes of Die Failure ","","3/25/2009: Gross Cracking "," Modes and Causes of Die Failure Metalife Presentation Jerald (Jerry) V. Skoff Jerry Skoff 1073 2000-01-23T23:36:06Z 1998-03-10T13:09:58Z 2009-03-26T04:34:24Z 64 628 35mm Slides 563482 196 9 9 11.9999 80 This presentation contains content that your browser may not be able to show properly. This presentation was optimized for more recent versions of Microsoft Internet Explorer. If you would like to proceed anyway, click here. "); array_files[198]=new Array(0,1,"http://www.badgermetal.com/slideshows/cavitation-slides/dc-cavitation-failure-28slides.htm","2009-07-12","3K","Cavitation revisited ","","=3/22/2009: Cavitation in die casting "," Cavitation revisited Metalife Presentation Jerald (Jerry) V. Skoff Jerry Skoff 1163 20 2000-01-23T23:36:06Z 1998-03-10T13:09:58Z 2009-03-22T23:29:01Z 866 35mm Slides 2154087 140 28 17 2 2 11.9999 80 This presentation contains content that your browser may not be able to show properly. This presentation was optimized for more recent versions of Microsoft Internet Explorer. If you would like to proceed anyway, click here. "); array_files[199]=new Array(0,4,"http://www.badgermetal.com/pdf/tl-steel-id-form.pdf","2009-07-12","232K"," tl-madison-kipp-form ","","","Badger Metal Tech, Inc. N60 W15088 Bobolink Ave. Menomonee Falls, WI 53051 262-252-3804 800-366-1973 262-252-3956 FAX thermallife@badgermetal.com Mandatory fields must be completed prior to releasing to our production department. Include steel type for each line item. 12345 C u s t o m e r N a m e and # (for B a d g e r U s e Badger will maintain on file furnace chart curves for the dies on this work order in the event that resulting rockwells are challenged. P e r s o n completing form marm 1 Company sign and print name Address City State Zip R e q u e s t e d return shippin g m e t h o d C o m m e r i c a l Carrier marm UPS me dm F ar Ex Contact Name Phone Shipper # 2 Purchase Order Qty 3 Description Size LxWxH Max 3 Steel Type 4 lbs m aom r Pickup Custr me m ar m other specify marm p l e as e indicate how tooling is marked for our identification m a Notes r m 5 Customer must use this form to communicate to Badger Metal the specifics on the parts for processing. B a d g e r - F o r m - t l 07 0 5- r e v- 1 "); array_files[200]=new Array(0,4,"http://www.badgermetal.com/pdf/sdce-1964-cavitation.pdf","2009-07-12","122K","sdce-1964-cavitation.pdf ","",""," "); array_files[201]=new Array(0,4,"http://www.badgermetal.com/pdf/pct-brochure.pdf","2009-07-12","1455K"," pctbroch-2004-3pages.pub ","",""," Todays modern manufacturing methods demand extremely high productivity levels with as little downtime as possible. The MetaLLfe® surface i treatment provides a means for attaining this as well as helping to reduce manufacturing tooling costs. WHAT IS IT? MetaLL ife® utilizes a well known principle of metallurgy regarding compressive stress layer generation in metals. Such a layer tends to reduce fatigue failure, and help retard or prevent crack initiation and propagation. The MetaLL ife® treatment involves impacting a tooling surface with a controlled micro media to induce a beneficial compressive stress layer on the surface of the steel. Three important changes occur as a result. ENCAPSULATING RESIDUAL LAYER - The generated compressive stress layer slightly work hardens the tool while replacing the normal surface tensile stresses that are left in a tool after sharpening or finish grinding thus making the tool more resistant to fatigue cracking. MOST EXISTING GRAIN BOUNDARIES ELIMINATED - The impaction of the tool helps obliterate most of the grain boundaries and stress risers which then prohibits micro-cracks from initiating or propagating in these areas. It is these cracks that lead to tool chipping or edge breakdown. ADDITIONAL COOLANT RESERVOIRS - At the time of surface impaction, tiny microscopic pockets are created that act as coolant reservoirs. These pockets trap lubricant, thus allowing a cooler operating temperature which helps extend tool life. The documented test results on the accompanying page indicate what some of our customers are experiencing regarding tool life improvement. Since MetaLLife® is not a coating or plating but an encapsulating metallurgical change in the tools surface, the tool may be resharpened without the loss of the compressive stress benefit on the cutting edge. Applications include all types of tool steel with the exception of carbide composition materials. Tap cross sections showing layer of compressive stress and micro-sized pockets which help retain lubricant .010 to .015 "); array_files[202]=new Array(0,4,"http://www.badgermetal.com/pdf/mfmag-apr2005-techupdate.pdf","2009-07-12","78K","mfmag-apr2005-techupdate.pdf ","",""," "); array_files[203]=new Array(0,4,"http://www.badgermetal.com/pdf/edm-brochure.pdf","2009-07-12","725K","edm-brochure.pdf ","",""," "); array_files[204]=new Array(0,4,"http://www.badgermetal.com/pdf/diptank-brochure.pdf","2009-07-12","457K","diptank-brochure.pdf ","",""," "); array_files[205]=new Array(0,4,"http://www.badgermetal.com/pdf/dfs-brochure.pdf","2009-07-12","1465K","dfs-brochure.pdf ","",""," "); array_files[206]=new Array(0,4,"http://www.badgermetal.com/pdf/dce-residual-stress-sep2007-Part1-jan2008-Part2.pdf","2009-07-12","3653K","dce-residual-stress-sep2007-Part1-jan2008-Part2.pdf ","","","US hrsttnPeening Stress Effects and Corrective nde o a ding Residual Action for Die Casting Tools ­ Part 1 Jerald V. Skoff, President Badger Metal Tech Inc. Menomonee Falls, Wisconsin Introduction and History Recently, NADCA prepared and is publishing a User Guide on Relieving Stress in Die Casting Dies. The guide discusses two means to accomplish this: heat stress tempering and shot peening. Much has been written about the benefits of heat stress tempering; however, proper shot peening technique remains a mystery or an unknown proven quantity for many die casters. This is the first article of a two-part series to explain some facts surrounding this type of mechanically induced compressive stress, along with the controls used to assure obtaining the maximum benefits from Badger Metal Techs proprietary Metallife® process. Part 1 will cover general peenings history, definition, stress curves, depth and manufacturing effects that shorten life and performance on a far too significant number of die casting dies. Part 2 will discuss Metallife®s numerous benefits, special controls that must be followed for maximizing those benefits, new technologies in the field and some case studies. D uring the 11th Century, a special brand of European swords were produced that had improved performance along with resistance to breakage. Most swords at the time were thick and heavy to keep them from breaking. A broken sword in battle meant permanent downtime and probable doom to the user. These heavy swords, however, took more physical energy and strength to swing, which slowed down the users reaction time...also not a good thing. If you had the money or were a king, you could go to Toledo, Spain, and buy the newest technology in swords. The cunning Toledo blacksmiths had developed a thinner, lightweight, well-balanced weapon that would hold a sharp edge and could be bent almost double, over and over, without breaking. No other sword makers could produce such an indestructible battle weapon, which made the Toledo swords famous to thi "); array_files[207]=new Array(0,4,"http://www.badgermetal.com/pdf/dc-brochure.pdf","2009-07-12","1319K"," Brochure - Die Casting ","",""," "); array_files[208]=new Array(0,4,"http://www.badgermetal.com/pdf/cwreprint-brochure.pdf","2009-07-12","94K","cwreprint-brochure.pdf ","",""," "); array_files[209]=new Array(0,4,"http://www.badgermetal.com/pdf/Heat%20Treat%20207-2006-charts-9pgs.pdf","2009-07-12","1509K","Heat%20Treat%20207-2006-charts-9pgs.pdf ","",""," "); array_files[210]=new Array(0,4,"http://www.badgermetal.com/pdf/2007-stress-relief-users-guide531.pdf","2009-07-12","329K"," Users Guide ","","","Users Guide for Relieving Stresses in Die Casting Dies Produced by Badger Metal Tech, Inc. & The North American Die Casting Association By Jerald V. Skoff ­ Badger Metal Tech, Inc. & William A. Butler - Bloomington, Indiana April 30, 2007 Relieving Stresses in Die Casting Dies Table of Contents Acknowledgements 1. Introduction 2. Executive Summary 3. Heat Checking in Die Casting Dies ­ A Technical Overview Stress and Die Casting Dies Research Results 4. Methods to Improve Die Life Thermal Stress Relieving (Tempering) Die Shot Peening ( MetaLL*ife®) 5. NADCA Recommendations 6. Feedback from Die Casting Companies 7. Summary and Recommendations Technical References Hold the control key and left click with mouse while on page in blue 3 4 7 10 10 13 19 19 21 28 30 34 37 2 Acknowledgements The editors would like to acknowledge the contributions of the following companies and individuals who provided technical assistance and editorial comment during the preparation of this Users Guide. Each of them has extensive experience in the die casting industry and both they and their companies can be contacted for additional information or services. · · · · · · Jerry Skoff, Badger Metal Tech, Incorporated, Menomonee Falls, Wisconsin. Dr. David Schwam, Case Western Reserve University, Cleveland, Ohio. Mark Baleja, Century Sun Metal Treating, Traverse City, Michigan. Joe Price, Paulo Products Company, St. Louis, Missouri. John Stocker, Schmolz-Bickenbach, Chicago, Illinois. Gene Hainault, Therm-Tech of Waukesha, Waukesha, Wisconsin. Return to table of contents 3 Relieving Stresses in Die Casting Dies I. Introduction The die casting industry depends upon expensive steel dies to produce components for its customers. Especially when used for the production of aluminum components, the life of the die casting die is a critical cost factor. Many times the cost of the die can be 10-20% of the cost of each part. For example, a die for a large automotive die casting may cost as much as 800,000. If the life of the die is 200,000 shots, the "); array_files[211]=new Array(0,4,"http://www.badgermetal.com/pdf/2005-05-dce-ask-the-experts.pdf","2009-07-12","150K"," AskTheExperts.indd ","","",""); array_files[212]=new Array(0,4,"http://www.badgermetal.com/pdf/2003-05-thermallife-article-dce.pdf","2009-07-12","515K"," Article PDf - Die Casting Enginer - 2003-05-thermallife ","","","Die Casting Engineer May 2003 Page 1 of 19 Submitted April 1, 2003 Author: Jerald (Jerry) V. Skoff - Badger Metal Tech, Inc. ­ Menomonee Falls, WI 53051 Major Advances in Ferritic Nitrocarburizing (FNC) Web URL note: You will note strings of underlined text starting with http:// at strategic locations in this article,. These are specific web URL (Uniform Resource Locator) addresses. This information, when typed in your browser or copied/pasted from the NADCA website magazine, will lead to the exact location on the Badger Metal Web site where expanded technical information is posted. In addition, this article will be reproduced and available on the Badger Metal Tech literature CD that is mailed in two forms...standard and business card size. By using this type of medium, we are able to keep technology information current. Introduction: Fully automated technologies to perform ferritic nitrocarburizing or ferritic nitro-carburizing (FNC) have been utilized by Badger Metal Tech since June 2001. It was then that the equipment was first introduced to the general public. In early March 2003, Badger Metal Tech, Inc. * received confirmation from the U.S. Patent and Trademark Office that TherMaLL ife (FNC) is a registered process (regs. #2660875 & #2660870) for use on tool steels. MetaLLife is also registered (regs. #1389443 & #2011719). The modern FNC equipment used guarantees repeatability by using a fully computer controlled and automated system. The equipment is the only one of its kind in the United States. With its nine bed stations, other types of heat treatment can also be performed. In this article, the FNC capabilities of a system which is fully automated and includes the wash, preheat, diffusion, and quench cycle will be discussed. In this article, FNCs history, types of nitriding, the basics, controlling parameters, the operation of automated equipment, benefits received, and validation will be discussed. Since it is being used extensively in the field, the combining of (MetaLLife (compressive stress texturin "); array_files[213]=new Array(0,4,"http://www.badgermetal.com/newsletters/pdf/2009-03-las%20vegas-apr-7-10-2009%20Expo.pdf","2009-07-12","152K"," Las Vegas Apr 7-10 2009 Expo ","","","Las Vegas Apr 7-10 2009 Expo Discu sse d topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS Special Die Maintenance Seminar for Vegas Expo Print this Newsletter Volume #028-03-09 IN THIS ISSUE mous e over for content & click button Badger Metal Tech, Inc. T09-074 - Die Maintenance & Repair If you are planning on being in Las Vegas for the Die Casting Congress from April 7th thru the 10th, make sure you sign up for the April 8th Die Maintenance and Repair conference at 2:00 PM in the Versailles Room 1-2 of the Paris Hotel. March 2009 We will be presenting 4 of our success stories that deal with different problems and solutions relating to the subject. The keynote speaker will be John Finn from GM. Following this will be Success Stories from various individuals followed by a panel discussion. The latest issue of the DCE (March 2009) gives the If you cant make the show or are complete line up on Page 33. planning not to go, you can still view our part of the presentation If you cannot go to the meeting, click pertaining to success stories from on the sidebar button. We are using MetaLLife® in a proactive or anticipating a large turn out for this Congress Session so sign up in reactive manner. advance if possible. Back to top Cavitation Effect Study Our initial presentation to NADCAs die material committee has been shortened and updated to include video and more graphics. Jerry Skoff Surfac e Engineering. Suc c es s Stories Click on the sidebar buttons to view both the videos and Power Point presentations which will give you long awaited insight into why your tooling experiences pitting, We now have published this in web breakout, and premature fatigue viewable format along with our failure. presentation on the baseline study of how fast tensile stresses build in Take a look at our Residual Stress die casting die even without study to confirm how fast stress pressure and velocity parameters. cracking develops. Page 1 Las Vegas Apr 7-10 2009 Expo Back to top 3. Uncheck: Users must "); array_files[214]=new Array(0,4,"http://www.badgermetal.com/newsletters/pdf/2008-09-gross-cracking.pdf","2009-07-12","161K"," Gross Cracking - Hard to Identi ","","","Gross Cracking - Hard to Identify u n d e rlin e d in the body may be clicked to a direct hyperlink for more info Clo se the hyperlinked box to exit the window and return to this newsletter Discu sse d topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS Gross Die Cracking A Hard to Quantify Failure Mode Print this Newsletter Volume #025-09-08 IN THIS ISSUE mous e over & click button Badger Metal Tech, Inc. For almost 26 years Badger Metal Tech has been extending the life and improving the performance of tooling for die casting dies, drawing forming stamping tools and other perishable tooling. For Die Casting dies, there is one failure mode that Badger Metal cannot remedy or prevent and is the most expensive mode of failure that can happen. Yet, many times the true cause is hard to determine and nail down since the culprit cannot be definitively identified. We trust by this newsletter that some useful information can be supplied as a reference tool should this problem ever happen to your tooling. By clicking the sidebar buttons, you can find out more about this often misunderstood failure. September 2008 These side bar buttons link to specific sections on our web site. There you will find useful information on what is believed to be the primary cause of these failures as identified by NADCAs Die Materials Committee. Steel Quality Heat Treat Quality Statistical Process Controls Gross Cracking is one mode of failure that cannot be fixed with MetaLLife®, TherMaLLife® or any other surface engineering technology. It is usually catastrophic in nature and most often requires replacement of the tooling. On the other hand, this failure mode is not related to MetaLLife®, TherMaLLife® or any other surface engineering technology. Its root cause is one of the above. Back to top The first step in solving a problem is recognizing that you have one. In the case of a Gross Cracking failure, it is imperative that the steels metallurgical properties be thoroughly analyzed. Page 1 They do, however "); array_files[215]=new Array(0,4,"http://www.badgermetal.com/newsletters/pdf/2008-06-hd-excellence.pdf","2009-07-12","112K"," Resurrect tooling with Metallif ","","","Resurrect tooling with Metallife and Thermallife - Excellence Award u n d e rlin e d in the body may be clicked to a direct hyperlink for more info Clo se the hyperlinked box to exit the window and return to this newsletter Discu sse d topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS How one company resurrected retired tooling Print this Newsletter Volume #024-06-08 IN THIS ISSUE mous e over & click button Badger Metal Tech, Inc. We would like to thank everyone in the industry that voted for us. As of result of your input, Badger received the coveted Supplier Excellence Award at the May 2008 Casting Expo in Atlanta Georgia. June 2008 Many of you use our web site as a resource. We will soon add a new section on our links page that addresses this need. Click here or on the sidebar button. On this page will be a link that lists those individuals that have had this We feel honored to have received happen to them and contacted us this award and would like to share it looking for a continuing career in die with the rest of the industry. Just casting. click here or on the left sidebar If you know of any job openings at button. your company or at other locations, Everyone is going through difficult there will be contact information on along with other times now. We receive calls every individuals week concerning companies that information. if you know of anyone are going out of business or that lost their job, tell them to get in someone has lost their job as a touch with us. result. Back to top Some of our customers in the field have been combining the benefits of our MetaLLife® and TherMaLLife® processes for several years now. We were asked to apply both of our processes in all the known possible combinations with no concern for cosmetic requirements. One question we are frequently The results surprised even us. Click asked is How hard is it to weld here or on the sidebar button for full and polish after these are information on our website. applied? In short, the die went from b "); array_files[216]=new Array(0,4,"http://www.badgermetal.com/newsletters/pdf/2007-12-changes-newyear.pdf","2009-07-12","91K"," http://www.badgermetal.com/newsletters/emailbmt/2007-12-changes ","","","Changes coming in 2008 to make us even better. underlined in the body may be clicked to a direct hyperlink for more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. Page 1 of 2 NEWS from Badger Metal Tech. Changes for the New Year and some useful gifts Print this Newsletter Volume #022-12-07 mouse over & click button Badger Metal Tech, Inc. One thing that is constant is change. This applies as well to Badger Metal Tech. Here is a preview of what is new, and you will be hearing about in 2008. New December 2007 IN THIS ISSUE You can click on any of these topics for more information or use the sidebar buttons to the left. If you want to learn more about Ron Karani, click on his photo in the left sidebar. We have created a page on our website that we call Speedlinks because it tells you everything you need to know about MetaLL ife® and Thermallife Click Here to view Speedlinks Page. Vice President/Owner DCE Part II Article on Residual Stress Effect & Correction Causes Cavitation Lamination Before Sampling Processing +25% or Process cost Guarantee Refunded Welding L + MetaL ife® Watch for Part II of our article on Residual Stress Affects in the Jan 2008 issue of DCE Part 1 was published in the Sept issue of DCE. You can download here. 2008 Badger Calendar Back to top Convert Units of Measurement How many times have you had to convert a dimension or unit but would have to look up a table or use your knowledge of math to do it. Badger offers a free conversion program that will do it for you. There Click here to get it. Once you use it, you will want to put it on your desktop for instant access. Convert any unit. Click here for a screen shot. This program is virus, malware and spyware free. No installation needed. Runs from exe. 9/10/2008 http://www.badgermetal.com/newsletters/emailbmt/2007-12-changes-newyear.htm Changes coming in 2008 to make us even better. is no installation. Just download the z "); array_files[217]=new Array(0,4,"http://www.badgermetal.com/newsletters/pdf/2007-09-cavitation.pdf","2009-07-12","115K"," file://G:bmtwebnewslettersemailbmt2007-09-cavitation.htm ","","","Page 1 of 2 Anything underlined in the body may be clicked to a direct hyperlink for more info Close the hyperlinked box to exit the window and return to this newsletter Discussed topics are boxed to reduce the need to scroll pages - read each box as a section. NEWS Cavitation Effect Study of Breakout and Lamination Print this Newsletter Volume #021-09-07 IN THIS ISSUE User Guide Links Badger Metal Tech, Inc. No money, No time. This is the fatigue, dilemma that faces die casters everyday. The money to do 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. September 2007 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 present to you for the first time a failure mode seen and studied extensively in fluid hydraulic systems that also applies to die casting molten metal but to date, no one has addressed even though it is listed as a mode of die failure. Use the side bars at the left to become For years and after countless papers on die more informed on cavitation effect and how it is shortening your tool life. Back to top 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. "); array_f