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The current head mold tooling is experiencing wear between the steam chest and mold plates leading to problems in molding and assembly. In the current design of our mold tooling, the aluminum mold plate (6016 T6) directly contacts the steam chest (6061 T6). The contact pressure and the thermal dynamics of the molding process cause the interface of the two aluminum’s to micro-weld and tear constantly thus creating wear as seen in the attachmnent. Modify the current solid steam chest design and return to a spacer plate design. The mold plates thickness will have to be trimmed by 0.5mm on the back side. Please refer to the attachment for guidance as to where the stock will be removed. Currently tests are being conducted to determine if the perimeter of the mold plates will be nickel plated or the whole mold plate will be hard anadized. Also verify that there is 0.5mm clearance between the ears of the mold plate and the steam chests. Refer to ct03159 for more information. The same amount of stock will be added to the spacer plates making them 10.025mm thick. The spacer plates will be hard anodized with a teflon impregnation. The addition of the spacer plates to the assembly will require the movable wall pugs and the bushing assembly to be updated also. Please verify that the dimensional stack up is not changed in any way. To accomodate the new design the toe clamp assembly will changed. The proposed solution is to revert back to the old design for the toe clamps. The seal groove will now be in the spacer plates. It is recommended to refer to ct03135 for more details. Make sure that the seal with the bigger diameter is included in the assembly file. The wear on the mold plates and the steam chest has been observed mostly on the lower tooling, therefore it is only recommended to update the designs on the lower tooling until more conclusive data is available.

File Attachments:

	File Name	Description	User Name	Upload Date
Delete	Mold+Tooling+Wear+Issue+-+Spacer+Design+Conversion.ppt	spacer plate info	(pzzgk5)	2/16/2006 6:34:04 PM

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Primary Part Information:   Select*

Program	Part Type	Part #	Design Phase	Location	PTE	Status
Inline 6	Head	12579960	Prod	Saginaw	Khan, Rafid	Complete - Approved

Impacted Part Information:

Program	Part Type	Part #	Design Phase	Location	PTE	Status
Inline 5	Head	12563261	Prod	Defiance	Hilvers, Alan	Waived
Inline 5	Head	12578265	Prod	Defiance	Hilvers, Alan	Waived
Inline 6	Head	12586656	Dev	Saginaw	Khan, Rafid	Waived
Inline 6	Head	12601753	Dev	Saginaw	Khan, Rafid	Waived