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Compressive Stress benefits of applying |
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Here are some facts regarding TherMaLL ifeÒ 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 TherMaLLifeÒ 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. TherMaLLifeÒ, 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.
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Topic |
Response |
| How sensitive is the compound surface layer to cleaning? | It is recommended that the TherMaLL ifeÒ surface be cleaned so as not to disturb the compound layer. No more than a 20psi glass bead, or Scotch-BriteÒ should be used. If more aggressive cleaning is required, we recommend reapplication. |
Can you weld over the process?
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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?
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Once a tool has developed thermal heat checking, TherMaLLifeÒ does not have the ability to close heat checks as does MetaLL ifeÒ. |
Is there a need to be concerned about distortion?
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TherMaLLifeÒ is performed at a safe temperature that is not only well below the austenitizing temperature of the steel but well below (at least 50 degrees F) the last temper temperature. Consequently, no distortion occurs during heating or quenching, which is also done in a controlled atmosphere to maintain the size, shape, and tolerance of the original tool. |
What is the difference between the TL** processes?
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Many recipes are possible depending on the tool steel being treated. In addition to time, there are also temperature, velocity, pressures, and gases that enter into each recipe. Basically each of these "TL" processes can contain many other criteria besides the time that the tool is in the controlled atmosphere. Beyond the time factor, we do not disclose the specifics of the processes, however, each recipe is tailored for the application. Does Mrs. Fields tell you what goes into her cookies? |
What criteria do you use to choose one "TL" process v/s another?
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When deciding on which recipe to use, we consider size, weight, steel composition, application, and configuration of the tooling. As a rule, smaller tooling require less time in the bed to reach saturation, however, the configuration of the tool also must be considered. Each recipe will generate specific compound layers on the surface and varying diffusion depths. Thicker diffusion lends itself to soldering, washout, and wear resistance. Thinner diffusion is better suited for solder, washout, and heat checking resistance. |
Will H-13 w/ TL out perform Anviloy?
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Anivloy because it does not contain iron is very resistant to the intermetallic attraction of the molten aluminum in die casting. Recent 2002 tests at Case Western have shown that Anviloy outperformed all of the test steels without any diffusion process applied. One must consider cost, machining, and brittleness of Anviloy steel when deciding on this material. TherMaLLifeÒ when tested on H-13 material showed similar positive benefits for solder resistance. |
| Does it chip or peel?
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Decarburization or "bluing" such as that which occurs when a tool has been abused during machining or grinding will have a tendency to flake off at the area of decarb. This is due to the total loss of carbon at the surface of the tool by overheating the steel when grinding or machining it. Sharp edges that
have not been properly machined are usually the most likely regions for this to occur. It is possible to apply MetaLL ifeÒ after TherMaLLifeÒ to NEW tooling that has been properly machined without spalling the compound layer. It is important to combine the two processes properly. When doing this there are special recipes that need to be utilized. |
| Applying over PVD coatings | Prior to application of it is required that any previous coatings be completely stripped or removed. Without this being done, it is not possible to have the proper interaction between the gases and tool steel that provides the diffusion and compound layer characteristics. |
| How often do I need to apply? | Normally the tool is processed once with the TherMaLLifeÒ process when it is new and after final approval. Some customers apply it again at the normal half life of the tool with a prior application of MetaLL ifeÒ to close up minor existing heat checks. |
| Applying PVD coatings over TherMaLLifeÒ |
With the exception of CrC, all common commercially available PVD coatings (including TiAlN, CrN, TiN) showed excellent adhesion characteristics when applied over either a TherMaLLifeÒ or MetaLL ifeÒ surface. |
| What about Lubricity?
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The TherMaLLifeÒ
surface is extremely hard and smooth. Because of this there is an added
lubricity factor, similar to that obtained when doing standard gas nitriding. If MetaLL ifeÒ has been performed prior to TherMaLL ifeÒ, the micro pockets formed add an additional means to retain applied lubricant. |
| Is there any type of hot work steel that cannot be treated? | For a proper TherMaLLifeÒ diffusion process, the desired temperature has to be at least 900 degrees F minimum with a preferred minimum of 1000 or better. Any type of hot work steel, such as maraging, that does not have a high last temper at this point would not be a candidate. Maraging is aged at about 950 degrees F or less and could possibly be put at risk if TherMaLLifeÒ is done at a higher temperature. We are currently evaluating this situation and doing some testing on both maraging and maraging weld done to H-13 material. As the results are available, we will post the information here and possibly in one of our email newsletters. |
| What about doing the process to Uddeholm's DievarÒ or 2367 material? |
There are some steels for die casting which diffuse more quickly. A special recipe
for TherMaLLifeÒ
has been developed for these steels that will assure a proper compound zone
thickness and diffusion depth.
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What assurance is there at this treatment will perform as advertised? |
TherMaLLifeÒ is not a panacea for all die soldering or failure problems, however, references by NADCA in their Die Care Maintenance User Guide (E501) and MetaLL ifeÒ in the Relieving Stresses in Die Casting Dies (#531) support the fact that these are both viable processes. In addition customer testimonies continue to show the successes the processes are having in the field. One major US Japanese die caster has all of their new tooling TherMaLLifeÒ processed to extend the die life and improve performance of automotive dies. |
| If a Stress Temper of the die after TherMaLLifeÒ is performed, what effect does this have on the process? |
The diffusion process is done at a higher temperature than normal stress tempering (1000 degrees F) so it does not affect the process. A stress relieve at a higher temperature or a sustained temperature close to the processing temperature will dissolve the diffused layer.
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Last Modified - Wednesday September 10, 2008 |
