1. White/ compound layer of 1880 Vickers (75+ Rockwell C)
2. Nitrogen enriched diffusion zone, .002 - .010" deep to support the compound zone
The metallurgical properties are diffused into the base material, therefore, the process is not a coating and it will not flake, peel or chip off.
WHAT ARE THE BENEFITS OF DYNA-BLUE®?
- High wear resistance- surface hardness, typically greater than Rockwell “C” 75.
- High corrosion resistance: up to 1000 hours when combined with our NITROWEAR M dry film lubricant • Lower co-efficient of friction, as low as .03.
- Low dimensional variation: .0001"-.0002 growth per side.
- Anti-galling & anti-sticking properties.
- Enhanced release properties and parting line durability on plastic injection molds.
- Resists soldering, heat checking, and washout on die cast.
- Resists wear from glass filled plastics up to 10 times longer than nitriding or chrome.
- Maintains excellent micro finishes.
- Not limited by component geometry or line of sight.
- 100% environmentally friendly.
- Better weldability than traditional nitriding or ion nitriding.
- Capacity 42"x 134" and 75"x 100" : up to 10 tons
- Hard surface hardness maintains ductility, durability testing has shown that DYNA-BLUE® can bend up to 90° without cracking.
- Overnight service is available
DYNA-BLUE (FERRITIC NITROCARBURIZING) MICROSTRUCTURE
The microstructure of a Ferritic Nitrocarburized treated sample consists of a hard (75+ HRC) compound zone of carbon and nitrogen with a nitrogen rich diffusion zone beneath for support. The hard compound layer increases wear and corrosion resistance, has high compressive residual stress to resist wear, heat checking and cracking. When combined with a layer of Steam Oxide on the surface it prevents atomic bonding of the steel surface with aluminum, plastic, etc and reduces the coefficient of friction.
Features
- 20,000 pound capacity
- Mold sizes up to 75” corner to corner x 110” long.
- DYNA-BLUE® Ferritic Nitrocarburizing
- DYNA-BRITE™ for high gloss levels or Class”A” finishes. A DYNA-BLUE cycle with a reduced blueing cycle is used along with a buffing/polishing process to give a chrome like finish
- Excellent temperature uniformity and heat transfer.
- Virtually no distortion.
- Fluidized Bed ensures uniform case on O.D as well as I.D., water jackets, bores, small holes, deep cavities.
- 2-3 day turnaround
“ A revolutionary new surface treatment is now available to dramatically improve the performance and tool life of Die Cast Tooling, Injection Molds, Hot Form Tools and Stamping Dies up to 10 times longer than PVD and CVD and Diamond coatings.
This new technology represents a joint venture between Dynamic Surface Technologies (formerly Dynamic Metal Treating), a Michigan Corporation with over 25 years experience in surface treating and HARD Technologies Pty Ltd of Australia, a metallurgical based R&D facility. This process represents years of research, testing, and real life case studies.
This unique new technology represents a significant improvement over existing coating technology by diffusing a hard Chromium Carbonitride Layer into the steel at low temperature. Surface wear and corrosion resistance are greatly enhanced compared to PVD as well as eliminating softening and distortion of the tooling typically experienced with CVD coatings. The DYNA-MAX process has significantly improved tool life compared to Chromium, Titanium and TIALN coatings by as much as 4 times.
Benefits
The DYNA-MAX process is a duplex diffusion process incorporating the DYNA-BLUE process with a low temperature (575C) Chromium Carbonitride deposition layer that does not soften the hardened steel matrix like CVD coatings. It also alleviates flaking, peeling, and delamination associated with PVD coatings. The DYNA-BLUE layer acts as a catalyst to diffuse the Chromium into the steel and also provides excellent support for the extremely hard (1520 Vickers) surface.
The combination of two surface techniques is commonly referred to as “duplex surface engineering”. This new development has combined the DYNA-BLUE process with a low temperature (575ºC) chromium thermo reactive deposition layer. This duplex process forms a hard chromium carbonitride surface layer that is diffused into the steel. This process is accomplished via a diffusion alloying reaction between the nitrogen from the nitrocarburized layer and the deposited chromium metal (6). The low temperature used does not soften the hardened steel matrix. Because the DST-Cr process forms a Chromium, Titanium, etc layer that is diffused into the surface that alleviates flaking, peeling, and delamination associated with PVD coatings. Titanium Nitride, Chromium Nitride, Chromium Carbide, are coatings that are deposited on the surface with no support or metallurgical bond. When the substrate goes into “plastic deformation or deflection” the hard coating flakes off. With the DST-Cr Process, support is provided with the Ferritic Nitrocarburizing process beneath the extremely hard surface.
HARDNESS TESTING OF DYNA-MAX (DST-Cr)
Vickers hardness testing was conducted using a load of 10µN on the surface layer and a 25 g load beneath the surface layer to the core. The surface layer was determined to be 1520 Hv and a diffusion zone from 1050 to 650 Hv. This also revealed that the nitrocarburized diffusion layer was retained after the DST-Cr process with a gradual hardness transition down to the core. This deep diffusion layer provides good support for the hard Chromium layer. It is also evident that the original core hardness of the H-13 steel was maintained.
PERFORMANCE TESTING
A tool performance study was done by a die cast facility (Mercury Marine) to provide real life test data of Ferritic Nitrocarburizing, DST-Cr and a PVD Chromium Nitride processes. This test revealed that the DST-Cr process had the greatest increase in tool life. The test tool was a die cast core located near an end gate with an extreme amount of wear. The FNC process yielded 10,000 shots, while the DYNA-MAX Cr yielded 59,425. The typical life for PVD Chromium Nitride was 18,000 shots.
NITROWEAR® is a proprietary and patented combination process where increased corrosion resistance above and beyond the corrosion resistance of DYNA-BLUE® is needed. The process incorporates proprietary coatings/oils after the part has been processed with DYNA-BLUE®.
- Nitrowear 1: DYNA-BLUE® plus water soluble oil for corrosion resistance of approx. 60-72 hours salt spray resistance per ASTM B-117, which is better than 409 stainless steel.
- Nitrowear 2: DYNA-BLUE® plus an oil/wax emulsion dip for corrosion resistance of approx. 96-120 hours salt spray resistance per ASTM B-117.
- Nitrowear M: DYNA-BLUE® plus dry film coating for lowest co-efficient of friction and highest corrosion resistance, up to 1000 hours salt spray resistance per ASTM B-117
DYNA-BRITE™ is a proprietary new process to minimize the polishing time needed after DYNA-BLUE® for high finishes needed on Lens/Lighting Molds, Class 1 finishes. This process will maintain the compound zone and thereby all the benefits of DYNA-BLUE® process while maintaining the micro finish.
DYNA-GLOSS™ is a proprietary new process to maintain/restore gloss levels on textured molds after the DYNA-BLUE® process. This incorporates a proprietary oxide removal process to insure gloss levels.
Maximizing the Heat Treating Process using a 10 Bar Vacuum Furnace and Fluidized Bed Tempering:
To maximize tool life of die cast tooling, hot form tooling, forging or casting tooling the heat treating process must be optimized In order to optimize the mechanical properties inherent in the steel. The 4 most critical factors we closely control are.
- Controlling the heating rate to control distortion with 12 thermocouples placed in the core and surface of the tools.
- Maximizing the austenitizing temperature to insure solution of vanadium carbides without causing grain growth.
- Maximizing the quench rate to increase fatigue strength, hot strength and wear resistance.
- Tempering in Fluidized Bed Furnaces to insure tools are not under tempered or over tempered. Other batch ovens/ furnaces are slow heating so that by the time the core is up to heat the surface may be over tempered or the core may be under tempered. The Fluidized Bed Furnaces heat uniformly and quickly, much like that of a pot of boiling water.
WHAT STEELS CAN BE VACUUM HARDENED?
The furnace was designed to harden tool steels, such as M-2, M-4, T-15, H-11,H-13, D-2, S-7, 420SS, CPM9V,10V, and precipitation hardening stainless steels.