CHROMIUM PLATING OF AUTOMOTIVE PRESS TOOLS

Materials
The DMI hard chrome plating process is suitable for most types of steel and for all types of flake
grey and nodular cast irons with or without alloying elements such as chromium, vanadium and
molybdenum. It is suitable for old and new tools and will plate over a wide range of nickel/iron
and other weld materials, flame hardened and laser hardened surfaces and tools incorporating
inserts, loose steel draw beads, etc.
Recommended weld material: Iron with 40 - 65% Nickel
Castolin Eutectic 2230
Messer Griesham Gricast 31
UTP 86FN
or equivilant.
Benefits
The DMI process deposits a thin layer (nominally 25µm - 0.001" thick) of hard chromium over
the working surface of the tool. This layer reduces surface wear, reduces the need for
lubrication during the drawing process and reduces scrap levels, reject levels and press down
time.
Die condition
The tool which DMI receives should be in a condition which is giving consistent, reliable panel
production. (Refer to sheet 2 for general polishing criteria). Surface defects such as damage
marks, weld edges, etc. which result in unacceptable panel conditions will not be filled by the
chrome layer and should be repaired prior to chrome plating. Surface defects which do not
result in unacceptable panel conditions can be left. Significant surfaces including draw beads,
draw radii and exterior panel punch surfaces should be in a smooth, clean condition. Air
release holes in exterior panel punches should have clean, sharp edge definition with no
significant fall off. Internal cavities within the die structure may cause problems with solution
ingress. It is therefore desirable that cover plates, base plates etc. are removed. All electrical,
hydraulic and mechanical attachments should be removed.
Aluminium nameplates may be damaged by the process and these should be removed.
The DMI process may discolour and possibly remove any paint.
Transport
The die should be opened up and sent to DMI as separate components, i.e. punch, die,
blankholder.
The working surfaces should be lightly oiled. The working surfaces should be protected during
transportation with a blank draw panel. A layer of bubble plastic between the die and panel is
desirable for further protection.
The dies are offloaded using an overhead crane. It is therefore necessary that the transport
used should allow access from above.
The dies should be secured to prevent movement during transportation.
The maximum trailer length is 40 feet and the maximum head room into the factory is 4 metres.
Return from DMI
The die will be cleaned and the plated surface lightly oiled and protected with bubble plastic
and a panel, if supplied.
SIZE AND WEIGHT LIMITATIONS
DMI(UK) DMI(Europe)
Maximum craneage 20 Tonnes Maximum craneage 20 Tonnes
Maximum size 5.4M x 3M x 2M Maximum size 6.3M x 2.5M x 2M
POLISHING OF AUTOMOTIVE PRESS TOOLS

It is important that acceptable panel quality (excluding the benefits achieved by chromium
plating) is achieved prior to sending the tool for chromium plating. Defects which affect
panel quality must be rectified. Defects which do not affect panel quality need not be
rectified.

Outer skin punches

Pre-polishing should only be carried out if the surface condition makes the tool unsuitable
for processing and should be the minimum necessary, with minimum stock removal.

The following general rules apply for both pre and finish polishing of outer skin punches.

Forming radii and other radii subject to panel movement should be polished to a good,
even finish with no sharp steps or edges.

Large, flat areas should be polished to a good, even finish. Polishing patterns should be
avoided as these may transfer to the finished panel.

Polishing should only be performed parallel to feature lines and never across them.
Polishing of feature lines should be kept to a minimum to avoid excessive stock removal
and distortion of the feature lines.

Polishing around air release holes should only be carried out using suitable equipment to
avoid any fall off around the air release holes.

Other areas should be polished to a good, even finish.

Other tools

Pre-polishing should only be carried out if the surface condition makes the tool unsuitable
for processing and should be the minimum necessary, with minimum stock removal.

The following general rules apply to both pre and finish polishing.

Forming radii and other radii subject to panel movement should be polished to a good,
even finish with no sharp steps or edges.

Flat areas should be polished to a good, even finish with minimum polishing pattern.

Beads should be polished to a good, even finish with no sharp steps or edges.

Other areas should be polished to a good, even finish.

DMI FAST TRACK DIE CHROMIUM PLATING

DMI standard turn around for dies is about 72 hours for a die set.

However, even this service is not always sufficient.

In response to the ever increasing demands imposed by 'just in time' press production
schedules which reduce the time available for the chromium plating of dies, DMI have
introduced the 'FASTRAK' die plating service.

For a small additional charge DMI offer a 36 hour or better turn around for chromium plating
of a typical mid sized die set such as a door outer, fender outer, etc.
On individual pieces DMI can provide same day or next day service in an emergency.

For example a customer regularly sends medium size dies, such as door outer punches, which
arrive at DMI at 6.30 a.m. and are completed and returned the same day.

Another customer sends medium to large size dies to arrive on a Saturday which are
processed and returned on the Sunday night.

This service is available seven days a week and during shut down periods, public holidays, etc.
CHROMIUM ADHESION

The key to good adhesion of the chromium layer to the base material is the preparation of the
die surface prior to chromium plating and the long term maintenance of the process control
procedures and process solutions.

DMI and Koka Chrome Industries have for many years been
developing and refining different methods of pre treatment to achieve optimum surface
conditions on customer's dies.

Various chemical pre treatments were tried and, although reasonably successful on thin
chromium deposits, the chromium layer had a tendency to break down under heavy load,
particularly when applied to a range of weld materials or when layer thicknesses of 15 microns
or more were applied.

The DMI pre treatment process combines highly controlled

mechanical and electro chemical components to ensure that the chromium adhesion is
unequalled even on the most complex of die surfaces.

Process control in accordance with our BS EN ISO 9002: 1994 Quality System maintains this
high standard.

Chromium thickness is maintained to the optimum requirements for each die.

SURFACE FINISH VERSUS BRIGHTNESS

There is a popular misconception that surface finish and reflectivity or brightness

are directly linked. This is not the case as a bright surface may not necessarily
provide a smooth surface when measured with standard surface measuring
equipment.

One of the main objectives of chromium plating of dies is to provide a smooth, low friction,
non stick surface which allows the material being formed to move smoothly over the
blankholder faces, draw radii and other forming surfaces and, at the same time, prevent
build up of particles of zinc on the surface of the die. This characteristic is a result of surface
finish rather than brightness. Tests have shown that there is an optimum band of surface
finish which provides the lowest friction characteristics.

As the surface finish improves, the coefficient of friction decreases. However, as

the surface finish improves still further, there comes a point when the coefficient
of friction begins to increase rapidly.

DMI have carried out trials with many of its customers, including leading Japanese and
European car manufacturers, to test different surface finishes and chromium thicknesses.

The DMI process is designed to produce absolute adhesion at all layer thickness
and the chromium is polished to a smooth condition where required to give
minimum friction and to resist the build up of zinc and other particles.

With its unequalled wealth of experience, DMI provide dies which are finished to
the best and most appropriate standards to provide optimum, long term perform-
ance and cost effectiveness and we will continue to work with our customers to
develop and improve specifications where required.
BASE MATERIAL COMPOSITION

Many different grades of cast iron and welding consumables are used to manufacture and
maintain draw tools.

DMI have, through it's plants in the U.K., the Netherlands and Spain, processed more than five
thousand parts for the European automotive industry and have the experience to provide our
customers with the quality, reliability and service which is essential.
The DMI hard chromium process is designed to achieve this quality, reliability and service
whilst still allowing our customers choice in the base materials and welding consumables
which can be used.

DMI process flake grey cast irons such as FC25 through to highly alloyed cast irons such as
GGG70.
Previous surface treatments such as flame hardening, laser hadening and induction hardening
present no problems. Plasma nitrided tools can be processed provided DMI are advised prior
to treatment that these tools have been plasma nitrided.

A wide range of welding comsumables can be accomodated.

Ideally, conventional iron based consumables containing up to 70% nickel should be used.
Hard edge welding consumables containing a high percentage of chromium should be
avoided.

DMI personnel are available to discuss these matters at any time.