Proven Results

Data from Real Die Casters

Name: PROLONG Surface Technologies
Address: 3840 Ohio Ave, St. Charles, IL, 60174, US
Telephone: (630) 762-6500

Named die casters, documented test conditions, and specific numbers. 75% downtime reduction on the automotive OEM controlled test. 80,000 to 100,000 shots on VascoMax 300 dies that previously ran 15,000.

Request a Quote (630) 762-6500

Seal groove

Customer Feedback

What Die Casters Say About Our Treatments

Lee Kittle · Muskegon Die Casting

“Heat check historically filed at 62mm bore is now non-existent at 70K shots. Previously required filing between 2,500–5,000 shots. Huge cost savings in rework, repairs, and uptime.”

Reported Outcomes

70K

Shots before any filing

Heat check at 62 mm bore

2.5K–5K

Previous filing interval

Matt Brown · The Port City Group

“Whatever improvements you make to die life, treat your inserts with Solvenite. The results will amaze you.”

Dan Norton · Anderton Casting

“Using Solvenite on VascoMax 300 Steel with Silafont 36. Untreated dies lasted 15K shots; now achieving 80K–100K shots. Ordered 7 dies with 3 more planned, all with Solvenite.”

15K → 80K–100K shots

Vern Moss · Minnesota Die Caster

“MaXXshot core reached 32,350 shots with minimal solder buildup. Light polish performed for first time. Performs much better than other tested coatings.”

32,350 shots · light polish first time

Case Study

75% Reduction in Tooling Downtime

Test conditions · Automotive OEM · 20-machine fleet · A380 · ~45 lb shot

An automotive OEM tracking downtime causes across a 20-machine die cast fleet identified breakout and heat check (coded “383 B/O” in their internal reporting) as the dominant failure mode. They selected Solvenite for a controlled A/B test against the existing baseline.

Four dies on the same job, same steel grade, same heat treatment. Two dies (C4 and C6) received Solvenite treatment. Two control dies (D11 and D12) remained untreated.

Treated dies showed a 75% reduction in total downtime compared to controls. Reductions measured across heat checking, polishing requirements, flash incidents, and tool room repair frequency.

75%

Total downtime reduction, C4/C6 treated vs D11/D12 control

Fig. 1 · Downtime composition by category · Untreated control

Die	Treatment	Downtime
C4	Solvenite	1.38%
C6	Solvenite	0.84%
D11	Untreated control	5.71%
D12	Untreated control	6.15%

Fig. 2 · Per-die totals · Controlled test

Case Study

MaxxShot on a Critical Seal Groove

Seal groove

MaxxShot-treated seal groove · Midwest die caster

Test conditions · 3 covers, cavities 3 & 4 · max 20Rz / 3.1Ra finish spec

A prominent Midwest die caster needed to maintain critical finish specifications (maximum 20Rz / 3.1Ra) on a high-volume seal groove application. The team tracked progressive material upgrades across three production covers, cavities 3 and 4.

H13 hardened to 46-48 RC cracked at 3,500 shots. Dievar at 50-52 RC pushed first cracking out to 6,500 shots. Untreated die life topped out at 30,000 shots with maintenance intervals at 13,000.

MaxxShot on Dievar pushed average shot life from 39,006 to 52,927, a surplus of 13,921 shots per cover. The customer's amortization analysis used $0.35 per surplus shot and excluded polishing reduction, making the documented payback conservative.

Customer engineering team