MoldMAX® and PROtherm® are Brush Wellman’s copper beryllium alloys specifically designed for the plastic processing industry. These alloys provide a unique combination of thermal conductivity and strength, which allow for :

	Shorter cycle times and reduced part costs
	Improved part quality leading to a substantially lower scrap rate
	3 times faster machining rates resulting in lower cost molds and shorter delivery times
	Processing that is similar to tool steels with no substantial processing changes required
	One million + cycles leading to lower maintenance costs
	A reduction in cost for Moldmakers
	Reduced cost and high part quality at a lower piece price for Molders

MoldMAX® provides strength and wear resistance similar to that of many tool steels, and a thermal conductivity that is three to four times greater than steel and comparable to aluminum. MoldMAX® is typically specified for full cavity and core inserts, blow mold pinch offs, neck rings and handle inserts; cavity and core sub inserts; injection mold components; and hot runner system injection nozzles and manifolds.

PROtherm® provides the highest thermal conductivity available in a mold material… ten times greater than steel and twice that of aluminum. PROtherm® also offers a hardness and strength that exceeds aluminum. PROtherm® is specifically designed for foam processing; core caps, hot runner systems and other applications where maximum heat removal or control are required.

Thermal Conductivity Advantage
Mold design that optimizes the superior combination of thermal conductivity and strength of these alloys results in rapid, more uniform heat removal from the plastic part. The immediate benefit is less post-mold warpage and shrinkage. Once molding parameters have been optimized, shorter cycle times and better dimensional control can be achieved. Manifold design with MoldMAX® and PROtherm® results in more uniform temperature control of the plastic melt. Delivery of a more uniform and predictable plastic melt to the mold cavity results in better quality control.

Wear Resistance Advantage
Mold life is primarily a function of a mold material’s ability to withstand abrasive wear and galling. MoldMAX® has shown excellent wear resistance as core and cavity inserts and injection mold components in direct contact with the plastic part. Strategic location of MoldMAX® and PROtherm® components and inserts in aluminum blow molds improves parting line maintenance and provides longer service life.

Corrosion Resistance Advantages
MoldMAX® and PROtherm®, both copper-based alloys, provide excellent resistance to hydrochloric acid, carbonic acid and similar decomposition products which may result from plastics processing. As a result, both alloys are ideal for applications involving potentially corrosive plastics, such as PVC.

Machinability Advantages
MoldMAX® and PROtherm® are readily machinable. In conventional machining operations, MoldMAX® and PROtherm® machine 3 times faster than tool steels. While the thermal conductivity of MoldMAX® and PROtherm® makes them slower to electrical discharge machine than steel, set up can be optimized to minimize this difference.

Weldability Advantages
Unlike steel and aluminum, MoldMAX® and PROtherm® molds are readily weld-repaired with out significant loss of strength to the mold body. Both TIG (GTAW) and MIG (GMAW) welding processes are suggested.

WeldPak® copper beryllium is recommended as a filler rod. WeldPak® is MoldMAX® rod that has been conveniently packaged in three foot lengths and stocked in 3/32", 1/16", 1/8" or a combination of these diameters.

Surface Treatment
Wear resistance, corrosion resistance and surface release of MoldMAX® and PROtherm® can be extended with standard surface treatments. MoldMAX® and PROtherm® can be coated with chrome, electroless nickel, titanium nitride and tungsten disulfide. Further information can be obtained from our Customer technical service department.

Reduced Cycle Time
Weatherchem Corporation, a plastic closure manufacturer, achieved a 41% cycle time reduction during injection molding of an in-ground sprinkler system control knob by modifying the existing tool steel mold with a MoldMAX® sleeve section and a PROtherm® central bubbler. In doing so, cycle time was reduced from 37 seconds to 22 seconds. Replacement of the sleeve section with MoldMAX HH® (high hardness) increased the efficiency of heat removal from the plastic part. A water channel was eliminated from the sleeve section based on the higher thermal conductivity of MoldMAX®. To eliminate concentration of heat in the sleeve section, PROtherm® was selected to replace the central bubbler.

Design Freedom
Carlon, a leading manufacturer of PVC pipe and conduit, modified an optic fiber conduit connector mold with MoldMAX HH®. The stainless steel core of the mold exhibited cracking at the base after less than 2000 cycles. Carlon took advantage of the unique combination of thermal conductivity and strength of MoldMAX® by simplifying the water channel configuration of the core. The resulting increase in core strength eliminated the cracking failure. Based on this experience, Carlon, a Lamson & Sessions Company, is specifying MoldMAX® and PROtherm® in additional injection mold designs to improve performance.

Availability
Mill hardened MoldMAX® and PROtherm®, HH and LH (low hardness), are available in standard sizes of plate, rounds and hollow bar. Specific dimensions, cut from standard size material, are available from our distributors.

MoldMAX® Core and Ejector pins, with a minimum hardness of HRC 40, are also stocked in 4", 8", 12" and 18" lengths in body diameters ranging from 1/8" to 1". Additional information is available from Brush Wellman’s Core and Ejector Pin Data Sheet.

For further information or to place an order, contact Brush Wellman’s Detroit Service Center, at :

Brush Wellman Inc.
Warren, MI 48093
800-521-8800
586-772-2700

Technical Assistance
Detailed information regarding material properties; specific application and fabrication assistance; and mold design parameters is available from Brush Wellman’s Technical Service Department in Cleveland Ohio at 800-375-4205 or 216-486-4200.