METAL CASTING 
Project Fact Sheet 
DIE LIFE EXTENSION: MATERIALS FOR CRITICAL 
BENEFITS 
APPLICATIONS & INCREASED PRODUCTION RATES 
Researchers anticipate a variety of benefits 
including energy savings associated with the 
increased production of die castings made 
from secondary aluminum versus virgin 
aluminum used in other casting methods. 
One million Btus are required to melt one ton 
of secondary aluminum whereas 20 million 
Btus are required to melt the same amount of 
virgin aluminum. Additional benefits include 
the lower process energy consumption and 
productivity gains associated with shorter 
production cycles. These gains will result in 
higher casting yield further reducing melting 
requirements. In addition, significant cost 
savings will occur due to a reduction in die 
replacement costs and associated downtime. 
Together, these benefits are estimated to 
result in annual energy savings of 6.4 trillion 
Btu by 2020. 
APPLICATIONS 
The results of this research can be applied 
throughout the die casting industry. They will 
address important industry concerns in 
extending the life of die casting dies. 
MATERIALS BEING IDENTIFIED TO DOUBLE THE LIFE OF DIE 
BRUSH WROUGHT NYBRIL FX/44RC 
BRUSH WROUGHT 360/35RC 
1"X1"X7", WC7 
CANDIDATE MATERIALS 
BRUSH CAST NYBRIL 360-1/34RC 
BRUSH CAST NYBRIL 360-2/35RC 
BRUSH CAST OMAX/24RC 
CSM PM MO/20RC 
CMW ANVILOV 1150/37RC 
KULITE ANVILOV /33RC 
CASTING INSERTS 
In die casting, parts can be manufactured in large quantity with desired 
mechanical properties and near net shapes at relatively low cost. Very complex 
shapes ranging in size from less than one inch, to fifty inches or more, can be 
made out of aluminum, magnesium, zinc, and copper with no additional 
machining. The design and performance of the steel die is critical in meeting the 
engineering requirements of the final casting. It controls not only the dimensions 
and tolerances of the final part but also the surface quality of the products. 
Many dies end their useful life when tiny cracks develop on the surface, leading 
to unacceptable marks on the cast part. Improvement in the die steel has a 
major impact on the dimensional stability, reproducibility, and surface quality of 
the product. 
Case Western Reserve University, in conjunction with the North American Die 
Casting Association, has been conducting a program of research to extend the 
life of die casting dies. This project is designed to show how the proper selection 
of die materials by composition and processing can improve die life. 
As part of that program, this project is seeking to double the life of die casting 
inserts exposed to the most severe die casting conditions. This will be 
accomplished by testing and comparative analysis of: high alloy tool steels; 
refractory and other non-ferrous high temperature die materials; and diffusion 
coatings. At the conclusion of the research, guidelines for the selective use of 
each will be provided. 
PERFORMANCE OF NONFERROUS DIE MATERIALS 
600 
500 
400 
300 
200 
100
0 
Proper selection of die materials by composition and processing can improve 
die life. 
TOTAL CRACK AREA (X106

m2) 
P.G. H13/OIL/49RC 
BRUSH CAST NYBRIL FX/49RC 
OFFICE OF INDUSTRIAL TECHNOLOGIES 
ENERGY EFFICIENCY AND RENEWABLE ENERGY • U.S. DEPARTMENT OF ENERGY
Project Description 
Goal: The goal of this research is to double the life of die casting inserts exposed to the 
most severe die casting conditions by testing, comparing, and providing guidelines for 
selective use of: high-alloy tool steels; refractory and other non-ferrous high temperature 
die materials; and diffusion coatings. 
Progress and Milestones 
Prior work conducted by Case Western Reserve demonstrated that dies produced from 
chromium-molybdenum-vanadium steels with about 0.40% carbon, a minimum of inclusions 
and segregation, and heat treated to a Rockwell C range of 45-50, provide good 
thermal fatigue resistance. With appropriate composition, optimized austenitizing temperature, 
and a fast cooling rate, these studies show that improved die life can be expected 
in most applications. However, under certain conditions and in specific locations 
these good quality tool steels are prone to early failure. The use of special inserts or 
cores can extend die life in severe conditions. 
Researchers will study the behavior of these materials from a basic microstructure 
standpoint and evaluate the relative behavior of candidate materials. Testing will require 
a thermal fatigue test that is more severe than has been used so far. Specific elements 
of the study will include: 
- the effect of increased alloy content; 
- an evaluation of non-ferrous high temperature die materials; 
- the effect of diffusion coatings; and 
- productivity improvements. 
Some of the alloys being tested include: 
- Allvac IN718, a nickel-base alloy 
- Carpenter SS464, a ferritic stainless steel 
- Brush Wellman QMAX, a beryllium-copper alloy 
This project was awarded in 1999 and a paper on this research was presented at the 
1999 NADCA International Die Casting Congress. In addition, the results of this work 
were presented to the Die Materials Committee of NADCA. Several members have tried 
the new materials on the applications that 1) improve both die life by avoiding soldering 
and allow higher production rates by at least 50% by solidifying the metal more rapidly, 
2) avoid die damage, and 3) increase the rate of production of the machines by 50%. 
PROJECT PARTNERS 
Case Western Reserve University 
Cleveland, OH 
North American Die Casting Association 
Rosemont, IL 
A. Finkle & Sons, Chicago, IL 
Alloy Tool Steel, Santa Fe Springs, CA 
Badger Metal Technologies, Menomonee Falls, WI 
Brush Wellman, Cleveland, OH 
Chem-Trend, Howell, MI 
CSM Industries, Cleveland, OH 
DCD Technologies, Cleveland, OH 
FPM Heat Treatment, Elk Grove Village, IL 
Hayes Lemmerz - CMI, Ferndale, MI 
Latrobe Steel Company, Latrobe, PA 
FOR ADDITIONAL INFORMATION, 
PLEASE CONTACT: 
Harvey Wong 
Office of Industrial Technologies 
Phone: (202) 586-9235 
Fax: (202) 586-6507 
Harvey.Wong@ee.doe.gov 
http://www.oit.doe.gov/IOF/metalcast/ 
Please send any comments, 
questions, or suggestions to 
webmaster.oit@ee.doe.gov. 
Visit our home page at 
www.oit.doe.gov 
Office of Industrial Technologies 
Energy Efficiency 
and Renewable Energy 
U.S. Department of Energy 
Washington, D.C. 20585 
December 2000