Cut Scrap and Labour Costs with Armoloy
Challenge:
A nitrided die was being used on zinc-coated blanks to produce outer panels for a van. The panel included a door support column which was partly visible,
but the die was picking up and scoring the panels. The result was too much scrap, plus down time to polish the die during the run.
Solution:
Armoloy can provide multiple benefits when used on nitrided dies. In this case, the die was Armoloy coated, eliminating pick up. The Armoloy coating provided other immediate and long-term performance enhancements as well. The Armoloy coating eliminated the scoring problems, and thereby, the need to polish panels, saving the customer $26,000 in material and labour per run. Armoloy also eliminated the need to polish the die between cycles, and allowed the customer to cut cycle time by more than 50%. Finally, the customer was able to run the die using only washer compound as a lubricant. All told, the Armoloy coating enhanced the overall performance of this nitrided die by eliminating pick-up, cutting scrap, saving labour costs and reducing cycle time.
Armoloy on heavy-Gauge
Challenge:
A manufacturer was having difficulty producing a hinge reinforcement from a heavy gauge, cold rolled material. This particular hinge reinforcement die was also nitrided and the customer was having trouble with pick-up, spitting and galling.
On a typical 3,000 piece run, production was stopped every 700-800 pieces in order to polish the die. Conventional chrome was tried, but would not adhere to the nitrided surface.
Solution:
The die was stripped of the chrome and the Armoloy coating was applied, primarily for Armoloy's lubricity and its 78 Rc surface hardness.
The added lubricity of Armoloy resulted in better material flow, while eliminated pick-up, prevented splitting and galling, and preserved the surface of the die. The result was a significant reduction in scrap and an increase in "up time". Instead of stopping to polish the die three to four times during a run, the die team now polishes the die only once every two to three runs.
Extend Die Life
Challenge:
A stamping plant was having problems with an outer bumper die for an older model that was in its last year of production. The die was running 20% scrap and it appeared that the die would not produce the current model year requirements.
However, remanufacturing the die for one year would have been prohibitive (in time and money), and the customer did not want to build a new die with a new model year on the horizon.
Solution:
Armoloy has been proven to be a cost effective alternative even on older dies. The solution was to have the components of the die Armoloy coated. The Armoloyed die sections cut scrap to zero. The die was used to fulfill production requirements with no problems, prolonging die life., increasing productivity, and cutting scrap.
Special Situations call for Armoloy
Challenge:
A door reinforcement die was being used to produce parts from a material that had a plastic film coating on one side and a zinc coating on the other.
The parts were splitting and galling.
The die could not produce acceptable parts even though the customer was using 15 sprayers to apply lubricant.
Solution:
When it comes to special solutions, Armoloy cannot be beaten. At the customer's request, Armoloy coated the upper half of the die. The Armoloy coating eliminated the scrap and downtime problems, and the customer went from using 15 sprayers to using only one - and the one sprayer still in use was necessary only because the part was hanging up on the uncoated half of the die! Whatever your situation may be, Armoloy (UK) Ltd will work with you to find a solution.
"Run Dry" with Armoloy
Challenge:
If you need increased lubricity, Armoloy is the answer. A manufacurer was forming parts on a nitrated wheelhouse inner die, but was getting substantial scrap despite flooding the panel with lubricants.
The parts were splitting and galling.
The die could not produce acceptable parts even though the customer was using 15 sprayers to apply lubricant.
Solution:
After Armoloy coating this nitrided die , the customer was able to " run dry " without lubricants and with minimum scrap . This customer was also able to reduce the size of the blank, resulting in a significant materials savings. Increased lubricity, reduced scrap, materials savings - find out for yourself how Armoloy will save you money.
Eliminate Pick-Up and Premature Wear
Challenge:
Armoloy can handle the heavy-duty assignments. A manufacturer was using a flame-hardened APV rail to die form a heavy gauge (55 mil) material,
but was experiencing scoring, pick-up and premature wear. The die was initially run with no coating, and later with conventional chrome-both with poor results.
Solution:
After the die was Armoloy coated, the scoring and pick-up were eliminated, and the die has not experienced any surface degradation to date. In this case, Armoloy's lubricity and surface hardness (78 Rc) were of great benefit to the customer resulting in significant cost savings.
Armoloy for Forming Zinc-Coated Panels
Challenge:
A manufacturer was having problems with a flame-hardened die used to produce truck top outers from zinc-coated panels.
The die was picking up dirt and the press line was having great difficulty producing acceptable parts.
Solution:
The Armoloy coating enhances die performances on all types of metals-including the stamping of zinc-coated panels. Because the Armoloy coating provides el hard (78 Rc), smooth, slippery surface, it was the perfect solutio for this situation. After the Armoloy coating was applied, dirt pic -up was eliminated and the quality of the parts was greatly improyed.
More Hits, Less Wear
Challenge:
A boot lid inner draw punch was Armoloy coated early in 1989. Here's what the manufacturer's staff engineer had to say about the performance of Armoloy:
- This draw punch has run approximately 550,000 strokes
- Armoloy tends to wear through with nice feathered edges, whereas other brands of chrome plating crack and chip leaving sharp edges and galls.
- This punch, as well as all other Armoloyed punches, dies, blank holders and flange steels, run dry without drawing compounds or oiling.
- Service life has been excellent as with all other Armoloy pieces.
Solution:
The Armoloy coating isn't restricted to only automotive dies. The appliance industry is also utilising the Armoloy coating and realising similar benefits. For example, in a deep draw application in which a dishwasher tub was being produced, the manufacturer was having severe galling problems forming 304 stainless steel. Since being Armoloy coated, the die has produced over a million parts and has been scheduled for stripping and re-coating as a part of its maintenance.
Hepco Motion
Challenge:
Hepco Motion is a world-leading manufacturer of linear motion systems and automation components servicing a wide array of industries including mechanical handling, aerospace, automotive, and packaging.
Hepco considered various surface engineering solutions to enhance the properties of their industry leading linear motion products
Solution:
They decided to go with a solution that gives a hard (in excess of 900HV), thin (~3μ), and durable surface with good lubricity, and improved corrosion resistance. This was the Armoloy TDC coating, consisting of electroplated chromium at both a high purity (99.6%) and well bonded to the surface (there is no flaking, cracking, peeling or chipping). Hepco have reported excellent durability and life for treated components and a great improvement in corrosion resistance across all their supply applications.