Transcript Honda – 3 year study Steel verse Aluminum

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Aluminum has 5 times better heat transfer
than P20 steel
Aluminum has almost 6 times better heat
transfer compared to H-13 Steel.
Molders have experienced a 20% to 40%
faster cycle time.
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Aluminum Mold can be machined up to 30% faster
overall with appropriate high speed CNC machines
and cutting tools specifically designed for
aluminum
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Polishing time is reduced.
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Aluminum is 1/3 the weight of steel.
Service Centers can ship aluminum within
1-3 days, versus steel.
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Aluminum alloys offer higher thermal
conductivity, so the parts are removed at a
lower temperature. This leads to better
dimensional stability of parts providing
higher yields on the molding process.
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Cast product with three North American Producers
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Available in North American up to 30" thick and 74" wide (only 20” thick at this width)
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This alloy is for low volume or prototype molds.
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No abrasive plastics
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Drawbacks
Heat transfer is slower due to the low copper content / Cycle times are going to be slightly
lower than other aluminums
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Hardness is low 70 HB
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yield and tensile strengths are lower than other aluminums available
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Because of the hardness a high polish is hard to achieve
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Benefits
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Cost - Weight .96 dense
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because its a cast plate cost is much less than rolled or forged block
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Machinability is very good due to the lack of copper content
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stability is the best of any aluminum
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Has great weldability
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because copper content is low the corrosion resistance is very high
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sizes available
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through hardness
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Trade Names:
Alpase – K100S & M 5
Vista – ATP-5 & Duramold 5
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Cast product with two North American Producers
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This alloy has higher yield and tensile strengths than 6061 with hardness very close to 6061
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can be used for low volume production and prototype tools
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sizes available 38 thick 94 wide
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Drawbacks
Machinability (This is within the aluminums available / Still would machine much better than steel)
Chips might stick to cutters gummy.
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hardness is low (again within the aluminums available) 82 to 90HB
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Polishability
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Benefits
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Cost compared to 6061/ 7000
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weldability
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heat transfer very high
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yield and tensile strength are high compared to 6061
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sizes available
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through hardness
Trade Names:
Alpase – M1
Vista – Duramold 2
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rolled plate
16 thick
84 wide
192 long
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Drawbacks
Machinability is poor
hardness 89 -96 HB
Polishability
Benefits
thermal transfer rate is high
cost compared to 7000 series
weldability
Trade Names:
Kaiser select
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Three available alloys besides 7075
available 28” thick in forged block
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Drawbacks
Weldability / Can be welded but you have to follow the welding instructions very
carefully
Stability - All 7000 series can move during machining if not stress relieved
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Benefits
BTu's are very high 88- 100
Machinability
Yield and Tensile strengths are very high
sizes available
Hardness 150- 180 HB
Polishability A mirror finish is achievable
Trade Names:
Aleris – Hokotol
Alcan – Alumold
7075 – General product
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Their approach for reviewing Aluminum Alloy
1. Met with key Aluminum Alloy Material Suppliers
2. Honda paid for 3rd Party Testing to validate Material composition,
mechanical properties, abrasion resistance and compression strength.
3. Concluded that Honda should begin working with its suppliers to build Aluminum Alloy Tools.
(ZQ/WQ)
4. Honda decided to build aluminum tools and pay for the backup Steel Tool
Purpose:
a. Review Clamping pressure
b. Review injection pressure
c. Evaluate Tool build efficiencies
d. Evaluate Process Cycle time
5. Honda paid for Texture plaque development to further understand Aluminum Alloy texture
capabilities as well as repair methods.
6. Monitor Tool Maintenance and durability concerns
7. Based on Low Volume Results, began focusing on High Volume
applications to validate AL Alloy durability.
Can the mold be crushed by too much
pressure?
Unit stress = load/area
Projection area of mold = 46 x74 = 3404 in2
Projection area of part = 955 in2
Contact area = 3404 - 955 = 2449 in2
Stress (2500 ton press) =5,000,000 / 2449 =
2,041.65 psi
7050 tensile strength 77,600 psi
In this example, the clamping stress is only 2.6 % of the
AL Alloy Tensile Strength
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Will Aluminum Alloy handle high Injection pressure
without failure?
Compressive strength of alloy – 77,600 psi
Maximum injection pressure at the front of
the screw (regardless of machine size) –
33,000 psi
Percentage –33,000 / 77,600 = 42.5% of maximum
at highest possible pressure
The parts are
removed at a lower
temperature, resulting
in less distortion and
higher quality .
7000 series welding improvements are
being investigated.
Recommendations
P20 / S55C Steel
4130 / sd18 Soft
Steel
7000 Series
Aluminum Alloy
M1 & & 7000
Hybrid
M1 Cast
100,000
500,000
1,000,000 1,500,000 2,000,000
Approximate Number of shots
2,500,000
3,000,000
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Investment savings through machining
efficiencies.
Process savings through improved thermal
conductivity. (cycle time)
Reduce number of molds and injection machines
required to mold the parts.
Different grades of aluminum can be applied
based on Program volume.
Lower injection and clamp pressure required as
compared to tool steel.
Plastic parts released from the molds at lower
temperatures, resulting in less product distortion.
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We would like to Thank Honda of
America Mfg., Inc. for allowing us
to utilize their data to continue to
educate the Aluminum Injection
Mold Industry.
Thank You!
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