die cast aluminum heat sinks for tank tracks
DESCRIPTION
Laser Deposited and Pre-Hardened Steel Rapid Tooling Case Western Reserve University / NADCA David Schwam. Die Cast Aluminum Heat Sinks for Tank Tracks. Material: A380 Size:4.5”x2.5”x1.15” Weight: 1.1 pounds. ABSORBS HEAT FROM THE RUBBER, EXTEND TRACK LIFE, PREVENT STRIP-OFF FAILURE. - PowerPoint PPT PresentationTRANSCRIPT
Laser Deposited and Pre-Hardened Steel Rapid Tooling
Case Western Reserve University / NADCADavid Schwam
Die Cast Aluminum Heat Sinks for Tank Tracks
ABSORBS HEAT FROM THE RUBBER, EXTEND TRACK LIFE, PREVENT STRIP-OFF FAILURE
Material: A380Size:4.5”x2.5”x1.15”Weight: 1.1 pounds
Key Advantage: Short lead time. 49,000 parts (x4) were die cast with this pre-hardened tool.
Industrial Partner: St. Clair Die Casting, St. Clair. MODie Material: Pre-hardened 42 HRC DievarLeadtime: Three weeks
Die Cast Aluminum Heat Sinks for Tank Tracks
Shovel Nut
DLA part.
Industrial Partner: Empire Die Casting-Twinsburg, OHDie Material: Pre-hardened 42 HRC DievarLeadtime: Three weeks (instead of 14 weeks)
Key Advantage: Two hundred prototype parts were initially required. Production run is expected to exceed 100,000. So far at 49,000. The projects is running productionwith the prototyping tool, thus saving the entire cost of tooling.
DRS’s Driver’s Vision Enhancer (DVE) Display Control Module (DCM) is a 10.4" liquid-crystal display (LCD) providing a rugged display technology to the warfighter on today’s digital battlefield.
Display Control Module
Warfighter Relevance
Objectives
Problem• Current tool building practices are costly and time
consuming• require sequential rough machining• heat treating• machining to final size• use steel that does not allow fast heat removal and
optimal control of the thermal profileObjective• Demonstrate rapid tooling methods
• Use of pre-hardened steels to shorten lead times and extend die life
• Use of high thermal conductivity materials including Toolox 44, Anviloy and laser deposited rapid and bi-metallic tooling to improve rate of production
Benefits
• Accelerate fabrication of parts made by metal mold technologies
• Rapid tooling for die and permanent mold casting– More adaptive to frequent changes in design than
traditional tool making methods– Can quickly provide small, prototype batches yet, if
needed, make production quantities
• Demonstrate increased productivity and better mechanical properties of the castings by use of high thermal conductivity die materials
Technical Approach
Use of high thermalconductivity materials(laser deposited H13 oncopper, Toolox 44 and Anviloy cores)
Utilization of pre-hardenedadvanced steels to shorten lead-time and lower tooling cost
Utilization of Pre-HardenedSuperior Steels to Shorten
Lead-Time and Lower Tooling Cost
Display Control Module
Implementation at Twin Cities Die Casting
• Anticipated production was 40,000 parts
• Using Pre-hardened tool steels of various types. Heat treat was 40 – 42 RC.
• Machining method was primarily High Speed but some Electro-Discharge Machining also.
Project Volume Increased
• Original plan was to cast no more than 40,000 parts.• Tooling started to show some washout and heat
checking around 20,000 shots. • Notified by customer that there would be a second
order coming after completing the first 40,000 parts.
Heat Check and Washout Inside after 24,000 shots
Heat Checking Outside after 24,000 Shots
Steel Repair Method
• Steel checked for hardness. Steel had softened through usage to 39–40 HRC down from 40-42 HRC.
• Cavity steel was ultrasonically cleaned, machined, welded and re-cut, polished and then nitrocarburized after 28,000 shots.
• Repair lasted balance of first order.
After Repair at 38,000 Shots
After Repair at 38,000 Shots
Tool Steel after First 40,000 Shots
Next Order is Being Processed for 20,000 Parts
• Steel has been polished and then Shot Peened.
• Nitride re-applied after last maintenance.
• Steel checks 39–40 HRC; no change from 20,000 shots.
• Estimated life to replacement is another 40,000 shots.
• Cost and time metrics needed
Use of High ThermalConductivity Materials:Laser Deposited H13 on
Copper, Toolox 44 and Anviloy cores
Rapid Tooling Method 1
*-Courtesy POM
Direct Metal Deposition of H13 on Copper - the POM Method
Die Cast Part for Evaluation of Improved Cores
The core is surrounded by molten aluminum therefore overheatsand solders. Extracting heat more efficiently from the core can lower temperature, prevent soldering and allow shorter cycle times.
H13 Deposited on Cu – ready for machining
H13/ Copper Core after 250 cycles
The core creeps due to insufficient stiffness and strength at high temperature.
Remedial ApproachesCaves in
Bulges out The distortion of the core seems to originate from insufficient strength and stiffness at the operating temperature. Anviloy and H13 cores do not suffer from this problem.
Priority 1 - Increase strength: use core as deposited w/o tempering (downside-lower toughness).
Priority 2 - Increase thickness of H13 layer(downside- slows down heat transfer). Use computer simulation
Technical Progress
• The life of the laser deposited core has been extended to 5,000+ shots.• A computer modeling effort is underway to
optimize the thickness of the laser deposited H13 layer.
• Other high thermal conductivity die materials (Toolox 44, Anviloy) are being tested.
• A current NADCA/NEMAK/GM project is leveraging this effort.
Finite Element Model
Axi-symmetric analysis model
Temperature variation along outer surface
300oF constant
1 cycle
cavity fill
solidification
Steel H13
Copper Alloy
Temperature and stress field at the end of cavity fill (deformation is enlarged by 100)
Temperature (oF) σVon Mises (Psi)
Project Plans
• High cooling rates the mechanical properties. Shown is the improvement in Dendrite Arm Spacing (DAS) and respective tensile strength caused by a water cooled core.
Improving Mechanical Propertieswith High Thermal Conductivity Cores
High thermal conductivity, cooledcores in die cast aluminum blocks
32
Effect of Thermal Conductivity of the Shot Block
Material on Cooling Time of Biscuit at 950oF
0
5
10
15
20
25
30
35
0 20 40 60 80 100 120 140
Thermal Conductivity(Btu/ft.h.F)
Coo
ling
Tim
e(s)
H13
Anviloy
3C CuBe
Toolox 44
• Continue Utilization of Pre-Hardened Superior Steels to Shorten Lead-Time and Lower Tooling Cost for Control Display Module• A computer modeling effort is underway to optimize the thickness of the laser deposited H13 layer.
Project Plans
Implementation
Conclusions
• Use of high conductivity alloys in die components can shorten cycle time significantly.
• In the present case, the cycle time dropped from 55 sec. for H13 to 40 sec.(13% )
• The life of a tempered, 40HRC H13/ Copper laser deposited core was 250 cycles. By using the core in the as-deposited condition at 51HRC, life was extended to 5,000+ cycles and going.
• The balance between strength and toughness is critical to ensure durability of the core. High strength is required to prevent distortion while high toughness avoids cracking.
Description Baseline Goal Target Date (Month/Year)
Progress % Accomp.
Toughness•Spray formed
6 ft-lb 8 ft-lb Dec 2008 7.75 ft-lb 87.5%
No. Shots•Pre-Hardened
10,000 shots(P20)
30,000 July 2009 20,000 in progress 50%
Enhanced cooling•Spray formed – Die Temperature
Die Surface
800oF
Die Surface 700oF
July 2010 720oF 80%
Improved
Elongation•Cooled core-
0.5% 2% July 2010 New task for 2009/2010
Project Metrics
JDMTP Criteria - Summary
Jointness B – Benefit to more than one service, but not jointly funded
Needs and Benefits • Needs : Short lead times for rapid prototyping and legacy parts. • Benefits: Up to 75% shorter lead time, depending on the part.• Benefits: 20% shorter cycle time
Transition • Parts under evaluation at Empire Die Casting-2007• Parts under evaluation at St. Clair Die Casting-2007• Production of new part at Twin City Die Casting• Composite cores in production at General Die Casters • Results disseminated through NADCA committee meetings, NADCA publications for industry, and the Metalcasting Congress
Leveraging • Building on previous AMC and NADCA/DOE work • Leveraged by current NADCA/NEMAK/GM project
Relevance to Sustainment of Weapons Systems
• Strengthen supply chain by increasing number of metal mold suppliers able to meet DLA requirements.• Shorten lead time for procurement of components for legacy systems.• Improved mechanical properties of components.
MRL 6 - Manufacturing capability to produce in a production representative environment
DLA - POC: Dean Hutchins ([email protected], 804-279-5033)
Problems:
• Standard tooling for metal mold processes requires long lead times
• High cycle times in the production of metal mold castings
Objective:
• Evaluate advanced cooling techniques and rapid tooling techniques to reduce lead times
Benefits:
• Demonstrate increased productivity by utilizing rapid tooling techniques and improve properties by incorporating high thermal conductivity die materials
Milestones / Deliverables
• Evaluation of toughness and thermal fatigue of dies with deposited materials
• Optimization of laser deposited H13 layer
Transition Plan
• The optimized laser deposited cores will be evaluated in production
Partners:– Case Western Reserve, Twin City Die
Casting, POM, DCD, NADCA, St. Clair Die Casting, Genral Die Casting, Empire Die Casting
Laser Deposited and Pre-Hardened Steel Rapid Tooling