Hitachi Metals, Ltd.

COLD WORKING TOOL STEELS

COLD WORKING TOOL STEELS SLD MAGIC

HOT WORKING TOOL STEELS

DIE STEELS FOR DIE CASTING DAC Series

PLASTIC MOLD STEELS HPM Series

PLASTIC MOLD STEELS CENA1

HIGH SPEED TOOL STEELS

COLD WORKING TOOL STEELS

1

COLD WORK TOOL STEELS

For high performance service

Abrasion resistance, Strength

Characteristics of YSS Cold Work Tool Steels HAP72 XVC5

P/M high speed steel Strength

HAP40

YXM4

HAP10

YXM1

Toughness

Strength Abrasion resistance

S-MAGIC

SLD

SLD8 Air hardened steel

ACD37

YXR7

HAP5R Matrix high speed steel

YXR3 ARK1

Toughness

YXR33 DAC

Excellent machinability

SGT Flame hardend steel

YCS3

Simplified small production

Free cutting and pre-hardened steel

DAC Toughness

• Comparison of charactistics YSS grade

Abrasion resistance

Pressure resistance

Strength at elevated temperature

Toughness

S-MAGIC

A

A

B

A–

SLD

A

A

B

B

ARK1

B+ A–

A

B

A

A A+

B+

A–

A–

A–

A

C D

SLD8

Hardenability

Distortion by heat treatment

Machinability Weldability

Standard hardness (HRC)

A+ A+

A+ A+

A–

B

58~62

B

C

57~63

A+ A+

A+

A

B

58~60

A

B+

C

58~63

A

B–

C

59~65

C

A+ B–

B

57~63

D

D

C A+

D

C

B

57~63

CRD

A– A+

YCS3

D

SGT

C

C B+

D

B

A

B

57~63

B

A–

C

B

C A+

D

ACD37

A

A

B

55~60

HMD5 HMD1

C

B

D

B





A

A

55~60

HPM1 HPM2T

D–

D

D

A–





A–

A

40

YXM1

A

A

A–

B

B

B

C

58~64

YXM4

A++

A+ A+

A+

B

B

C

62~66

XVC5

A+++

A++

C

B

C

D

63~67

YXR7

A

A++ A+

B B–

B–

A

A

A

B

B

A–

A

A

B

B

B A+

A+

A+ A++

A

B

B+ B+

C C+

61~65

YXR3

C+

54~58

A

A+

A

A

B

C

58~62

A

B–

C

62~65

A

C+

C

64~67

A

C–

D

68~71

SLD10

YXR33

B

HAP5R

A

HAP10

A+

A

A

HAP40

A++

A+ A++

A++

A–

HAP72

A+++

A+++

A+++

C

A B A–

(A is the uppermost level and + indicates higher performance)

2

58~61

COLD WORK TOOL STEELS

Applications and YSS grade Features YSS grade

Main applications

Features

S-MAGIC (NEW)

Cold work dies for high-tensile steels, SUS, mass production, and general use.

High performance cold work tool steel attaining both extended mold lifespan and outstandingly easy mold fabrication. 60~62 HRC with high temperature. tempering. Excellent wear & galling resistance.

SLD

Cold work dies for general use, forming roll, shear.

Cold work die steel with high abrasion resistance for general use, excellent harden-ability and minimal quench stress.

ARK1

Dies for printed circuit board, die plates, stripper plates.

Cold work die steel with high toughness and improved machinability. The same heat treatment conditions as SKD11.

SLD8

Rolling dies, cold forging dies.

62HRC or more with high temperature tempering, superior machinability and toughness.

SLD10

Rolling dies.

Extremely highest hardness in die steels. 62-64HRC, with excellent toughness.

CRD

Drawing dies, blanking dies for mass production, brick liner.

Cold work die steel with highest abrasion resistance.

YCS3

Press forming dies, jigs and tools.

Carbon tool steel for small production to be quenched in oil , easy to heat-treat.

SGT

Dies for deep drawing, gauges.

Cold work die steel with superior machinability for generaluse; Be careful with quenching large dies and wire electric discharge machining.

ACD37

Dies for deep drawing, gauges.

Vacuum quenched and air quenched steel, improved for SGT as to hardenability and wire electric discharge machinability.

HMD5 HMD1

Dies for deep drawing.

Steel for flame hardening, resulting in high hardness and small strain even with air quenched; good weldability.

HPM1

Press forming dies for small production, jigs and tools.

Free cutting and fully hardened steel, good nitriding characteristics.

YXM1

Cold forging dies, cold heading dies, slitter.

High speed steel with high abrasion resistance and toughness for general use.

YXM4 XVC5

Cold forging dies, drawing dies.

High speed steel to prevent from abrasion, seizure and deformation under high pressure.

YXR7

Rolling dies, cold forging dies, roll, cold forging panches, blanking panches.

Matrix high speed steel, extremely highest toughness in 62-65HRC. available to vacuum quenching.

YXR3

Dies to be used for cracking or chip breaking resistance.

Matrix high speed steel for general use, extremely highest toughness in 58-61HRC.

YXR33

Cold forging dies, warm forging dies.

Matrix high speed steel extremely highest toughness in high speed steels.

HAP5R

Cold forging dies, fine blanking dies.

Standard hardness 56-58HRC. Extremely tough Powder Metallurgy process high speed steel.

HAP10

Fine blanking dies.

Extremely tough Powder Metallurgy process high speed steel.

HAP40

Press forming dies for mass production, roll.

P/M high speed steel with high abrasion resistance and toughness for general use.

HAP72

Cold plastic working dies of long life, high performanced IC molds.

P/M high speed steel with high hardness and highest abrasion resistance.

3

Type and Chemical Compositions Grade YSS S-MAGIC SLD

JIS equivalent

Chemical Composition (%) C

Si

Mn

S

Ni

Cr

W

Mo

V

Co



1.00

0.35



High performance cold work tool steel

Patent pending SKD11

P

1.50

0.25

0.45

≤ 0.025 ≤ 0.010



12.00

ARK1

Patented steel

High toughness cold work tool steel

SLD8

Patented steel

High strength cold work tool steel

CRD

SKD1

2.10

0.25

0.45

≤ 0.025 ≤ 0.010



13.50









YCS3

SKS93

1.05

0.35

0.80

≤ 0.030 ≤ 0.030



0.40









SGT

SKS3

0.95

0.25

1.05

≤ 0.025 ≤ 0.010



0.75

0.75







0.85

0.25

2.10

≤ 0.025 ≤ 0.010



1.20



1.50





ACD37 HMD5

Flame hardened tool steel

Original steel

COLD WORK TOOL STEELS

HMD1 HPM1

Patented steel

0.12

0.30

0.90

≤ 0.025 ≤ 0.10

3.00





0.30

Cu2.2

Al1.0

YXM1

SKH51

0.85

0.25

0.35

≤ 0.025 ≤ 0.010



4.15

6.50

5.30

2.05



YXM4

SKH55

0.85

0.25

0.35

≤ 0.025 ≤ 0.010



4.15

6.50

5.30

2.05

5.00

XVC5

SKH57

1.25

0.25

0.35

≤ 0.025 ≤ 0.010



4.15

10.00

3.50

3.45

10.00

YXR7

Original steel

Matrix high speed steel

Patented steel

Extremely tough matrix high speed steel

YXR3 YXR33 HAP5R

P/M high

HAP10

speed steels

1.3











5.0

3.0

6.0

4.0



HAP40

SKH40

1.3











4.0

6.0

5.0

3.0

8.0

HAP72

Patented steel

2.1











4.0

9.5

8.2

5.0

9.5

Extremely tough P/M high speed steel

4

Heat Treatment

(1)Annealing

(2)Holding time at hardening temperature

1. All material is delivered as spheroidized annealed condition. 2. When used after reforging, spheroidized annealing is to be done before hardening. 3. Stress relief annealing is to be done in order to remove stress occured by cold working such as cold drawing, cold rolling or cutting and machining. • Heating temperature: 650-700°C • Holding time: 1h/25mm thickness

• High speed tool steel

1. Preheating time 1st stage: 30 minutes for every 25 mm of the tool at 500-550°C 2nd stage: (holding time X 2) at 850°C 3nd stage: (holding time X 2) at 1,050°C Preheating is (holding time X 2) at 900°C for small thickness (50 mm max.) and simple shape tools, and wherever facilities are limited. The first stage can be omitted for small tools.

2. Holding time at hardening temperature (holding time) Thickness (mm)

Furnace type

5

10

20

30

40

50

60

70

80

90

Holding time (sec)

60

90

160

240

280

350

390

420

440

495

Thickness X multiple

X12

X9

X8

X8

X7

X7

X6.5

X6

X5.5

X5.5

Time

Note: Use the holding time in the salt bath as the immersion time.

• Cold die steels, alloy tool steels and carbon tool steels

1. Preheating time 1st stage: (holding time X 2) at 500-550°C 2nd stage: (holding time X 1) at 750-800°C (Unnecessary for SK, SKS)

Except that preheating can be omitted wherever an electric furnace is used or for small tools (50mm or less thickness) and simple shape tools.

2. Holding time at hardening temperature (holding time) Furnace type Salt bath or electric furnace

Thickness (mm)

Time

Holding time (min)

≤ 15

25

50

75

100

125

150

200

300

15

25

40

50

60

65

70

80

100

Note: Using salt bath needs preheating and the holding time used as the immersion time.

(3)Holding time at tempering temperature Thickness (mm) Holding time for tempering (h)

≤ 25

26~35

36~64

65~84

85~124

125~174

175~249

250~349

350~499

1

1.5

2

3

4

5

6

7

8

Note: Apply this standard to tempering at 500°C or more, and increase elongate tempering time to tempering temperature X 1.5 for 250-500°C and holding time X 2 for tempering temperature less than 250°C

(4)Dimensional changes after heat treatment 0.25 Radial direction Dimensional change rate (%)

COLD WORK TOOL STEELS

Salt bath

0.20

Longitudinal direction

0.15

0.10

0.05

0

S-MAGIC SLD ARK1 SLD8 ACD37 1,025°C 1,025°C 1,025°C 1,025°C 850°C 505°C 200°C 520°C 530°C 200°C

SGT 825°C 200°C

YCS3 YXM1 YXR7 YXR3 YXR33 HAP10 HAP40 800°C 1,200°C 1,160°C 1,150°C 1,140°C 1,130°C 1,130°C Hardening temperature 200°C 575°C 560°C 570°C 580°C 570°C 570°C Tempering temperature

5

Heat Treatment (5) Standard heat treatment conditions Annealing Temperature (°C)

Hardening Hardness (HBW)

Tempering

Temperature (°C)

Temperature (°C)

Hardness (HRC)

480~530 Air cooling

≥ 60

S-MAGIC

830-880 Slow cooling

≤ 255

SLD

830-880 Slow cooling

≤ 248

1010-1040 Air quenching 1000-1050 (980-1030) Air quenching (Oil quenching)

150~200 Air cooling

≥ 58

ARK1

830-880 Slow cooling

≤ 248

1010-1040 Air quenching

480~530 Air cooling

≥ 58

SLD8

830-880 Slow cooling

≤ 248

520~550 Air cooling

≥ 60

CRD

830-880 Slow cooling

≤ 248

1020-1040 Air quenching 930-980 (950-1000) Oil quenching (Air quenching)

150~200 Air cooling

≥ 61

YCS3

750-780 Slow cooling

≤ 212

790-850 Oil quenching

150~200 Air cooling

≥ 63

SGT

750-780 Slow cooling

≤ 217

800-850 Oil quenching

150~200 Air cooling

≥ 60

ACD37

750-800 Slow cooling

≤ 235

830-870 Air quenching

150~200 Air cooling

≥ 58

HMD5 / HMD1

825-875 Slow cooling

≤ 235

Flame hardening

550~570 Air cooling

≥ 63

560~580 Air cooling

≥ 64

550~580 Air cooling

≥ 64

550~580 Air cooling

≥ 61

YXM1

800-880 Slow cooling

≤ 255

YXM4

800-880 Slow cooling

≤ 277

XVC5

820-880 Slow cooling

≤ 285

YXR7

800-880 Slow cooling

≤ 241

YXR3

800-880 Slow cooling

≤ 241

(1)1220-1240 (2)1200-1220 Oil quenching (1)1230-1250 (2)1210-1230 Oil quenching (1)1230-1250 (2)1210-1230 Oil quenching (1)1160-1180 (2)1120-1160 Oil quenching (1)1150-1170 (2)1130-1150 Oil quenching

560~590 Air cooling

≥ 58

YXR33

800-880 Slow cooling

≤ 241

1080-1160 Oil quenching

550~600 Air cooling

≥ 55

HAP5R

820-870 Slow cooling

≤ 269

530~580 Air cooling

≤ 58

HAP10

820-870 Slow cooling

≤ 269

530~580 Air cooling

≥ 61

HAP40

820-870 Slow cooling

≤ 277

1120-1160 Oil quenching (1)1170-1190 (2)1120-1170 Oil quenching (1)1190-1210 (2)1120-1190 Oil quenching

560~580 Air cooling

≥ 64

HAP72

820-870 Slow cooling

≤ 352

1180-1210 Oil quenching

560~580Air cooling

≥ 68

(1) Simple shape tools (2) The others, especially needs toughness *Sample size is 15mm square or round and 20mm length based on the JIS Standard hardness test.

(6) Hardenability

(Half temperature time: time requred to cool from the austenitizing temperature to half that temperature) {(austenitizing temperature + room temperature) / 2}

70

60

Maximum diameter of bar for which the center hardness of 60HRC can be achieved

YXR7(1,180°C) SGT(850°C)

50

CRD (980°C) YXM1(1,180°C) SLD(1,025°C)

XVC5 (1,230°C)

40 Hardness (HRC)

COLD WORK TOOL STEELS

YSS grade

30

20

10 1.0



20ø

70ø

180ø



2.0

3.0 4.0



6.0 8.0 10

170ø

20

30

40



550ø 60

80 100

Half temperature time (min)

6

200

400

600 8001,000

[ :air quenching,

:oil quenching]

Quenched and tempered hardness curve S-MAGIC

ARK1

SLD

70

70

70 1,050°C 1,050°C

65

65

1,010°C

60

Hardness (HRC)

55

1,000°C 55

55

50

50

45

45

45

0

40

100 200 300 400 500 600 Tempering temperature (°C)

CRD

40

0 100 200 300 400 500 600 Tempering temperature (°C)

1,030°C

60

50

40

0

100 200 300 400 500 600 Tempering temperature (°C)

SGT

YCS3

70

70

70

(Oil quenching)

(Oil quenching) 1,000°C

850°C

925°C

40

30

YCS3 (820°C Oil quenching) 50

Hardness (HRC)

975°C 50

60

60 Hardness (HRC)

Hardness (HRC)

60

30

0 100 200 300 400 500 600

800°C 825°C 50

40

40

30 0

Tempering temperature (°C)

ACD37

100 200 300 400 Tempering temperature (°C)

YXM1

68

68

66

66

100 200 300 400 500

HAP5R 68

1,240°C 1,220°C

66 1,180°C

1,200°C

64

64

60 880°C

62 1,180°C 60

Hardness (HRC)

855°C

Hardness (HRC)

64

62

1,160°C 1,140°C

62

60

1,160°C

58

58

58

56

56

56

54

0

Tempering temperature (°C)

830°C

Hardness (HRC)

COLD WORK TOOL STEELS

1,025°C

60

Hardness (HRC)

Hardness (HRC)

1,030°C

65

1,120°C 1,100°C

100 200 300 Tempering temperature (°C)

54

500 520 540 560 580 600 620 Tempering temperature (°C)

7

54

500 520 540 560 580 600 Tempering temperature (°C)

Quenched and tempered hardness curve YXR7

YXR33

YXR3

70

66

62

64

60

62

58

1,160°C

66

1,160°C 1,140°C

64

Hardness (HRC)

Hardness (HRC)

1,180°C

62 1,120°C

1,175°C 1,150°C 1,125°C

60 58 56

Hardness (HRC)

68 1,140°C

56

1,120°C

54 52

54

50

52

48

50

46

60

48

500 520 540 560 580 600

66

550

600

44

700

58 56

1,025°C

70 1,160°C 1,180°C 68

66 Hardness (HRC)

64

62

520 540 560 580 600 Tempering temperature (°C)

1,200°C 1,220°C

66

64

60 1,100°C 1,075°C 1,050°C 1,025°C

58

54 52

650

HAP72

1,200°C 1,180°C 1,160°C 1,140°C 1,120°C

68

Hardness (HRC) 1,100°C 1,075°C 1,050°C

600

72

64

60

550

Tempering temperature (°C)

70

1,200°C 1,180°C 1,160°C 1,140°C 1,120°C

62

500

HAP40

HAP10 70 68

500

Tempering temperature (°C)

Tempering temperature (°C)

Hardness (HRC)

COLD WORK TOOL STEELS

58

56

520 540 560 580 600 Tempering temperature (°C)

8

62

60

500 520 540 560 580 600 Tempering temperature (°C)

Properties

•Abrasion resistance

Specific abrasion volume(mm3/mm2• mm)X10-7

Hardness (HRC)

S-MAGIC

62.0

SLD

60.0

ARK1

59.0

SLD8

62.5

YCS3

60.0

SGT

60.0

ACD37

60.0

YXM1

65.5

XVC5

67.0

YXR7

65.0

YXR3

59.0

YXR33

58.0

HAP5R

60.0

HAP10

64.0

HAP40

67.0

HAP72

70.0

0.5

1.0

1.5

2.0

The Ogoshi type abrasion tester was used to determine abrasion resistance of matched SCM415 samples, tested under the following conditions: abrasion length of 400 mm, load of 67N, and friction speed of 0.78 m/sec.

• Toughness (kgf/mm2)

(N/mm2) YXR3

600 ARK1

400

Bending strength

YXR7

YXM1

HAP10

5,000

HAP5R

S-MAGIC

SLD

300

HAP40 YXM4 XVC5 V60

SGT CRD

4,000 HAP72

56

58

60

3,000

V50 V40

200 100

6,000

62 64 66 Hardness (HRC)

68

70

72

2,000

(J/cm2) 200 Charpy impact value

(kgf-m/cm2) 20

1,000

YXR33

10R Charpy impact value

500 Bending Strength

COLD WORK TOOL STEELS

YSS grade

YS

M

150

15

YXR3

10

S-MAGIC

4

SLD 2

9

100

ARK1

6

0 54

HAP5R

56

58

60 HA P1 0 HAP40 YXR 7 YXM YXM4 1

60 62 64 Hardness (HRC)

40

HAP7 2 XVC5

66

68

70

20 0

Available Size Range (by Rolling)

•Round and Spuare Bars

(Unit: mm)

Shape diameter or parallel side

Dimension

Round bar 0

0.5

1

1.5

2

2.5

3

3.5

4

5

5.5

Square bar 6

6.5

7

7.5

8

8.5

9

9.5

0

1

2

3

4

5

6

7

8

9

9.5

180 170 160 150 140 130 120 110 100 90

COLD WORK TOOL STEELS

80 70 60 50 40 30 20 10 0

•Flat Bars Width (mm)

50

Thickness (mm)

65

75

90

105

130

6 10 13 16 19 25 32 38 50 65 75 100 110 120 130 140

10

155

185

205

255

305

355

405

460

The BEST 10 New Prodacts Nippon Brand Prize of The Nikkan sinbunn.

TOOL Steel SLD MAGIC

The arrival of a new die and mold material seeking longer mold lifespan and total cost reduction. • Considerably prolongs lifespan of molds. • Prevents scuffing of high-tensile steels during bendingand drawing. • Reduces reworking man-hours through minimal heatand surface treatment deformations. • Shortens mold processing time via enhancedmachinability. • Lowers tool expenses by extending cutting tool lifespan.

Striving for the 21st century global standard.

1

Concept SLD-MAGIC (S-MAGIC) is the revolutionary next-generation die steel attaining both extended mold lifespan and outstandingly easy mold fabrication.

SLD-MAGIC Relationship Good

S-MAGIC Features Wear resistance

High hardness of 62HRC improves wear resistance by approximately 35%*.

Surface treatment

Adherence between the coating layer and steel after surface treatment (CVD and other methods) is improved by approximately 30%*.

Wear resistance

COLD WORK TOOL STEELS/SLD-MAGIC

M : Materials Magic A : Advanced G : Gratifying I : Innovative C : Cold work die steel

Heat treatment

Minimal deformation during heat treatment for a reduction of approximately 40%* in dimensional changes.

S-MAGICTM

SKD11 SLDTM

8%Cr Steel 10%Cr Steel

ARK1TM

Machinability Machinability improved by approximately 35%* *Hitachi Metals comparison: Comparison against 8%Cr steel (Hitachi Metals product name:SLD 8), a modified steel of SKD11.

Wear resistance

Machinability

Comparison of Properties

S-MAGIC increases wear resistance by approx. 35% compared with 8% Cr steel due to the control of carbide morphology.

62HRC

8% Cr steel

62.5HRC

10% Cr steel

60HRC

SKD11

60HRC

Grade

S-MAGIC

8% Cr Steel

10% Cr Steel

SKD11

Hardness (HRC)

60-62

61-63

59-61

58-60

Wear resistance

Ohgoshi-method wear test S-MAGIC

Good

Surface treatment*

Wear resistance is improved.

Toughness

Machinability

0

+

Dimensional change by heat treatment Weldability

0.1 0.2 0.3 0.4 0.5 0.6 0.7 (mm3/mm2.mm)

+

Specific wear volume Excellent

Work material: SCM415 Friction distance: 400m Friction speed: 0.76m/s Load: 67N

Poor

*Surface treatment properties are based on adherence between the coating layer and steel after surface treatment. 8%Cr steel and 10%Cr steel offer improved machinability for better processing that reduces the volume of hard carbides within steel, but are inferior to SKD11 in terms of wear resistance and galling.

2

Scuffing resistance S-MAGIC shows no scuffing on Hat Testing simulating practical mold wear phenomena.

Scuffing Test Initiation point and direction of scuffing

Bead

Observation direction

COLD WORK TOOL STEELS/ SLD-MAGIC

Work

Schematic of test conditions

Appearance of work Sample

Scuffing Observation

Die

Punch

Holding Pressure

Scuffing Test Conditions Press : 80ton Cranck Press Velocity V : 40~75spm (19.2~36m/min) Holding Pressure Ps : ~2.4ton/cm2 Length of Stroke : 60mm Lubricant : Anti-rustoil applied and wiped away Work : High-tensile-strength steel (590MPa) Thickness 1.6mm (No plating) Surface Roughness of the mold: Polished by #1000 (Ra=0.04µm)

S-MAGIC

SKD11

No scuffing

Mold surface

Scuffing

Mold surface

Work Surface

Work Surface

Surface treatment S-MAGIC can be treated with hard coating (CVD, TD

layer and steel after 3-time surface treatment by approx.

treatment etc.) under the same conditions as SKD11 S-MAGIC improves adherence between the coating

30% when compared with 8%Cr steel, due to optimum alloy design.

Coating Layer by CVD method

Adherence between the coating layer and steel after 3-time CVD treatment.

Scratch test

Thickness 8µm

Index (SKD11=100)

S-MAGIC Improved adherence 8% Cr Steel 10% Cr Steel SKD11

50µm

60

70

80

90

100

Index

Adherence

Weldability S-MAGIC shows lower susceptibility of cracking by welding compared with SKD11 and others.

Pre-heating temperture

S-MAGIC

SKD11

8%Cr Steel

10Cr Steel

1

3

2

3

Under 100°C 100~200°C 200~300°C Over 300°C ranking of anti-cracking

Welding rod: SKD61 grade φ4.0mm Welding current: 130A (AC) : Cracking occured at 3rd layer : No cracking at 3rd laye

16 3

Toughness

10R-notched Charpy impact value

S-MAGIC is superior to SKD11 in toughness. It can be used as a countermeasure to chipping and cracking with low temp. tempering.

S-MAGIC

Low temp.: 200°C High temp.: 510-520°C

Toughness is higher

Low temp. tempering High temp. tempering

8% Cr Steel

10% Cr Steel

0

10

20

30

40

(J/cm5)

10R-notched Charpy impact value

Rotating bending fatigue test

Fatigue strength

(N/mm2) 1100

S-MAGIC (61HRC)

1000

S-MAGIC shows improved fatigue strength in comparison to SKD11 due to the control of carbide morphologies.

Stress

COLD WORK TOOL STEELS/SLD-MAGIC

SKD11

900

8%Cr Steel (62HRC)

800 700

SKD11

(60HRC)

600 500

103

104

105

106

107

Cycles

Physical Properties Thermal expansion coefficient X10-6/°C

20~100°C

20~200°C

11.7

12.3

Annealed

Quenched and tempered

7.77

7.76

Ac1

Ms temperature

Specific gravity

Transformation temperature

850°C

166°C

4

Thermal conductivity W/m·K

Young's modulus GPa

Room temperature

28.9

209

Heat Treatment

Standard Heat Treatment Conditions

It is possible to heat treat S-MAGIC under the same conditions as SKD11.

Annealed Hardness

Austenitizing

Tempering

Hardness (HRC)

≤ 255HBW

1010~1040°C Air quenching

480~530°C Air cooling or 150~250°C Air cooling

≥ 60

(HRC)

S-MAGIC

66

SKD11

64

Hardness

It is possible to obtain maximum hardness (60~62HRC) with tempering at around 500°C where dimensional change is near to zero, achieving both high hardness and less dimensional change.

8%Cr Steel

62 60 58

10%Cr Steel

56 54 52

Austenitizing 1030°C 0

100

200

300

400

500

Tempering temperature 2Hr, Twice

600 (°C)

Dimensional change after heat treatment Secular change of S-MAGIC after high temp. tempering is almost equivalent to that of SKD11, and smaller than 8% Cr steel. It is possible to reduce secular change via low temp. tempering, sub-zero treatment or stabilizing.

(%)

Dimensional change rate

COLD WORK TOOL STEELS/SLD-MAGIC

Quenched and tempered hardness

8%Cr Steel

0.10

10%Cr Steel SKD11

0.05

S-MAGIC

*A

*A

*B

0 Austenitizing 1030°C -0.05

0

100

200

300

400

500

Tempering temperature 2Hr, Twice

600 (°C)

*A: Minor dimensional change *B: Minor dimensional change with maximum hardness

Secular change / Dimensional growth Low temp. tempering

S-MAGIC

High temp. tempering

8% Cr Steel 10% Cr Steel Size of test pieces: 45T X 90W X 200L Austenitizing: 1030°C Low temp. tempering: 180°C X 2times High temp. tempering: 520°C X 2times Measure: 200mm direction Dimensional change after 6 months posterior heat treatment

SKD11 -0.005

0

0.005

0.010

0.015

0.020

Dimensional change rate

5

0.025 (%)

Heat Treatment

Secular change/Dimensional change

S-MAGIC shows smaller in dimentional change difference in the longitudinal, width and thickness directions, compared to SKD11 or 8% Cr steels.

Small difference between L and W direction

S-MAGIC

Upper L (Longitudinal) Lower W (Width)

8% Cr Steel 10% Cr Steel SKD11 -0.05

0

0.05

0.1

S-MAGIC shows narrow deviation of dimensional changes by heat treatment, as a result, the better dimensional tolerance can be attained.

S-MAGIC

SKD11

Standard deviation : 0.021 Number of measurement : 70 -0.1

Standard deviation : 0.042 Number of measurement : 70

Narrow deviation

0

-0.1

Wide deviation

0

0.1 0

5

10

15

0.1 0

5

Direction

Grade

W

(mm)

(mm)

Mold set up time

-0.030 -0.010

46

S-MAGIC L

250

+0.010 +0.004

W

295

-0.090 -0.031

L

250

+0.130 +0.052

54% reduction of mold ajusting time after heat treatment

100(Index)

SKD11

Example of dimensional change for insert type mold. 15 Width

Longitudinal

6

15

(%)

Original demensional demensional Change Dimension Change ratio

295

10

frequency

frequency

For example, in case of separation type molds, mold set up time was largely decreased because of narrow dimensional deviation.

(%)

Deviation comparison of dimensional changes of actual mold after heat treatment.

Dimensional chauge by Heat Treatment (%)

COLD WORK TOOL STEELS/SLD-MAGIC

Dimensional change ratio

Machinability S-MAGIC improves machinability on face mill by over twice that of SKD11 and by approx. 35% compared to 8% Cr steel. It also demonstrates superior machinability using other tools.

ø125 Face Mill Machinability is improved

S-MAGIC 8% Cr Steel

Work: Annealed condition Tool: Coated carbide chip, 1chip only Cutting speed: 120m/min, Dry Feed: 0.13mm/blade Depth of cut: 2Z X 90Wmm, Cutting distance: 4m

10% Cr Steel SKD11 0

0.1

0.2

0.3

COLD WORK TOOL STEELS/SLD-MAGIC

Tool Wear

0.4 (mm)

End Mill Mold processing time is shortened due to enhanced machinability.

Work: Annealed condition Tool: End mill ø8 (Co-HSS) Cutting speed: 30m/min,Downcut,Wet Feed: 0.05mm/tooth Depth of cut: 15Z X 0.5Wmm, Cutting distance: 5m

S-MAGIC 8% Cr Steel 10% Cr Steel SKD11 0

0.1

0.2

0.3

Tool Wear

0.4 0.4 (mm) (mm)

Drill The lifespan of cutting tools is increased, thus reducing direct purchasing costs of tools.

Work: Annealed condition Tool: Drill ø5 (Co-HSS) Cutting speed: 20m/min, Wet Feed: 0.05mm/ev Depth of hole: 25mm, 200Holes

S-MAGIC 8% Cr Steel 10% Cr Steel SKD11 0

0.1

0.2

0.3

0.4

Tool Wear

0.5 0.5 0.6 0.6 (mm)

ø63 High feed cutter Work: Annealed condition Tool: Coated carbide chip Cutting speed: 150m/min, Dry Feed: 1.3mm/tooth Depth of cut: 1mm, Cutting distance: 60m

S-MAGIC 8% Cr Steel 10% Cr Steel SKD11 0

0.4

0.8

1.2

Tool Wear

7

1.6 1.6 2.0 2.0 (mm) (mm)

Machinability S-MAGIC can enhance tool lives because of lower cutting tool temperatures.

Cutting tool temperature comparison CEPR6080 (ultrafine particle WC) (ø8 X 6NT TiAIN)

COLD WORK TOOL STEELS/SLD-MAGIC

S-MAGIC

Color of chips

Temperature at tool surface (°C)

200

SKD11

180 160 140

10%Cr

8%Cr

S-MAGIC

120 100 80 n=3981min-1(V=100m/min)

60

Ap=12mm Ae=0.4mm OH=25mm

40

Dry with Air Blow KITAMURA M/C 11kw

20 0

1

2

3

4

(m)

Cutting Length SKD11 (Tempered color)

Grindability Grindability of S-MAGIC is better than those of SKD11 and 10% Cr steel, and almost equivalleut to 8% Cr steel.

Grindability comparison as a function of diffenent grinding wheels Grinding test conditions • Work 50 X 90 X 200L (Heat treated condition) • Machine: Reciprocal Type • Grinding Wheel a: Alumina Single Crystal b: Alumina c: Alumina + Other ceramics

S-MAGIC 8% Cr Steel 10% Cr Steel

a b c

SKD11 0

1

2

3

4

5

6

7

Grindability ratio

8

9 10

Grinding Conditions • Wet Traverse Grinding • Velocity of Wheel 33m/sec • Table velocity 0.33m/sec • Undercut 5µm/pass • Cross Field 5mm/lap • Spark out 1lap • Total undercut 0.1mm • Grinding ratio Ground off amount/wear of wheel • Grinding ratio is higher the better

8

Application Examples In addition to prolonging the lifespan of molds, S-MAGIC also enables remarkably easy mold fabrication, thereby contributing to total cost reduction and shorter processing times in the automobile and mold industries.

01 Bending die for automotive parts

COLD WORK TOOL STEELS/SLD-MAGIC

Inner parts Work 440MPa (t3.2)

02 Blanking die for automotive parts Function parts Work 590MPa (t7.0)

03 Blanking die for electrical appliances Electrical appliances Work Film

04 Blanking die for electrical appliances Optical parts Work SPCC (t0.8)

05 Blanking die for electrical appliances Liquid crystal panel parts Work SUS304 (t0.3)

Present condition

Evaluation

Grade

SKD11

S-MAGIC

Hardness

59~61HRC

60~62HRC

Heat treatment

High temp. Tempering

High temp. Tempering

Surface treatment

CVD (TiC)

CVD (TiC)

Lifespan

1,300 pcs

156,000 pcs

Cause

Severe galling

Less galling

Present condition

Evaluation

Grade

SKD11

S~MAGIC

Hardness

58~60HRC

58~60HRC

Heat treatment

170°C Tempering

170°C Tempering

Machinability

Bad

Good

Lifespan

15,000 pcs Max.

40,000 pcs carrying on

Cause

Severe chipping

Less chipping

Present condition

Evaluation

Grade

SKD11

S-MAGIC

Hardness

58~60 HRC

58~60 HRC

Heat treatment

530°C Tempering

530°C Tempering

Machinability

Bad

Good

Lifespan

650,000 pcs

1,020,000 pcs

Cause

Early wear out

Less wear

Present condition

Evaluation

Grade

SKD11

S-MAGIC

Hardness

60~62HRC

60-62HRC

Heat treatment

200°C Tempering

480°C Tempering

Machinability

Bad

Good

Lifespan

100,000 pcs

100,000 pcs carrying on

Cause

Burr (Wear out)

Reduce wear by half

Present condition

Evaluation

Grade

8%Cr Steel

S-MAGIC

Hardness

60-62HRC

60~62HRC

Heat treatment

505°C Tempering

480°C Tempering

Dimensional change

0.05%

-0.01-0.02%

Lifespan

30,000 pcs

40,000 pcs carrying on

Cause

Burr (Wear out)

Less wear

Scuffing

Mold lifespan significantly improved

Chipping

Mold lifespan more than doubles

Mold lifespan 50% up

Mold lifespan doubles

Mold lifespan 30% up

Note: The above-listed data is for application examples only and this data does not assure performance. It is not suited for molds with EDM finished surface that require a high degree of mirror finish such as plastic molds.

9

Present condition

Evaluation

Grade

SKD11

S-MAGIC

Die for hydroforming

Hardness

56HRC

58HRC

Exhawst pipe Work Steel tube

Heat treatment

High temp. Tempering

High temp. Tempering

Distortion by heat treatment

Very hard to adjusting the upper and lower die blocks clue to large dimensional changes

Reduction of adjusting time of the upper and the lower die blocks

Machinability

Bad

Improved. Adjusting is finished only by one chip used.

06

COLD WORK TOOL STEELS/SLD-MAGIC

07 Die for cold press Automobile parts Work Hight-tensile -strength steel

Present condition

Evaluation

Grade

SKD11

S-MAGIC

Hardness

58~60HRC

60~62HRC

Heat treatment

High temp. Tempering Large dimensional ohange

High temp. Tempering Deviation is reduced to 1/2. Ajusting time is reduced

Surface treatment

TD

Cause

Ball End Miuing Exchanging chips quite offen

TD The number of exchanged chips is reducedto 1/5~1/10 compared to SKD11. Feed rate is increased to 1.7 times.

Present condition

Evaluation

Grade

SKD11

S-MAGIC

Die for cold press

Hardness

58~60HRC

60~62HRC

Inner parts Work 440MPa (t2.3)

Heat treatment

High temp. Tempering

High temp. Tempering

Surface treatment

TD

Dimensional Changes by TD is within 5/100

Lifespan

5500 pcs

Continuing beyond 15,000

Problem

Scuffing

08

Present condition

Evaluation

Grade

SKD11

S-MAGIC

Die for cold press

Hardness

59~61HRC

60~62HRC

Inner parts Work 780MPa (t2.3)

Heat treatment

High temp. Tempering

High temp. Tempering

Surface treatment

TD

09

Machinability

Bad

Problem

Mochinabiliry and dimension change

Mold adjusting time is reduced because of small dimension change of upper and lower die blocks by heat treatment

Dimensional Changes by TD is small The life of chips used is 10 times longer than SKD11 cases.

Small dimension deviation

Mold Iifespan is improved by almost 3 times.

Small dimension changes after TD treatment

Note: The above-listed data is for application examples only and this data does not assure performance. It is not suited for molds with EDM finished surface that require a high degree of mirror finish such as plastic molds.

10

HOT WORKING TOOL STEELS

1

Characteristics of YSS Hot Work Tool Steels Warm forging 56~58HRC

YXR33

Precision hot forging 47~56HRC

High temperatrure strength, Wear resistance

HOT WORKING TOOL STEELS

MDC-K

DAC45

YEM-K

High performance die casting 43~53 HRC

DAC40 High speed hot forging 47~54HRC DAC10

DAC55 DAC3

FDAC

DAC (SKD61)

DM (SKT4)

Toughness

2

General purpose hot press/forging 40~48HRC

Applications and YSS grade Features

HOT WORKING TOOL STEELS

Grade YSS

JIS equivalent

DAC

SKD61

DAC3



Hot forging dies,

General-purpose hot-working tool steel used in a wide range of

Extrusion dise, Die casting dies.

applications.

Hot forging dies, Extrusion dise.

excellent heat crack resistance and wear resistance.



Extrusion dies.

DAC55



Die casting dies.

YEM-K



Hot forging dies.

MDC-K



Hot forging dies.



YXR33



DM

FDAC

SKT4



working press dies, high-hardened Al extrusion dies.

Extrusion dies.

DAC40

YXR3

greater toughness than DAC, and helps avoid cracking in hot-

Steel for precision die casting and hot-working press die which has





A hot-working tool steel which has improved hardenability and

Die casting dies,

DAC10

DAC45

Features

Applications

Die casting dies, Hot forging dies.

Hot forging dies.

Hot forging dies, Anti-meltdown insert pin.

Hammer dies.

Dies for small lot, Simple dies Holding lock.

Al extrusion die steel and hot-working press die steel which has better high-temperature strength and softening resistance than DAC. Tool steel for large or squeeze die casting moulds with excellent heat crack resistance. Hot-working tool steel with the improved high-temperature strength and toughness of JIS-SKD7 steel. Very high-strength hot working tool steel with the improved toughness of JIS-SKD8. Has great high-temperature strength and outstanding crack resistance, and is suited for hot-working press dies requiring wear resistance and high Si-Al die-cast molds requiring erosion resistance.

High-toughness matrix high speed steel. High-toughness matrix high speed steel for hot-working tools, and excellent wear resistance and crack resistance. Can withstand high-temperature loads such as in warm-and hot-working precision forging dies.

Tool steel for hammer dies.

Free-cutting hot-working tool steel.

3

Chemical compositions of YSS hot-working tool steels Chemical composition

Grade YSS

HOT WORKING TOOL STEELS

JIS equivalent

C

Si

Mn

0.39

1.0

0.40

S

P

Ni

Cr

W

Mo

V

Co



5.15



1.40

0.80



DAC

SKD61

DAC3

(Original steel)

High toughness die steel

DAC10

(Original steel)

High-strength die steel

DAC40

(Original steel)

High-strength Al extrusion die steel

DAC55

(Original steel)

High-strength and toughness die steel

YEM-K

(Original steel)

High-strength die steel

MDC-K

(Original steel)

High-strength die steel

DAC45

(Original steel)

High-strength die steel

YXR3

(Original steel)

Matrix high speed steel

YXR33

(Original steel)

Matrix high speed steel

DM

SKT4

0.55

0.25

0.85

0.030 ≤ 0.010

FDAC

SKD61 Free cutting

0.39

1.00

0.65

0.030

≤ 0.030 ≤ 0.010

0.130

1.65

1.20



0.35

0.15





5.15



1.40

0.55



*Harmful impurities such as S, Cu and Ni are restricted to below JIS levels using Hitachi Metals' own high-quality raw materials.

4

Heat Treatment Standard heat treatment conditions for YSS hot-working tool steels Annealing

HOT WORKING TOOL STEELS

Grade

Temperature

Tempering

Quenching Hardness (HBW)

Temperature

Temperature

Hardness (HRC)

DAC

820-870 Slow cooling

≤ 229

1000-1050 Oil cooling(Air cooling)

550-650 Air cooling

≤ 53

DAC3

820-870 Slow cooling

≤ 229

1000-1050 Oil cooling(Air cooling)

550-650 Air cooling

≤ 53

DAC10

820-870 Slow cooling

≤ 229

1010-1030 Oil cooling(Air cooling)

550-650 Air cooling

≤ 53

DAC40

820-870 Slow cooling

≤ 229

1000-1050 Oil cooling

550-680 Air cooling

≤ 53

DAC55

820-870 Slow cooling

≤ 229

1010-1030 Oil cooling(Air cooling)

550-650 Air cooling

≤ 53

YEM-K

820-870 Slow cooling

≤ 229

1000-1050 Oil cooling(Air cooling)

550-650 Air cooling

≤ 53

MDC-K

820-870 Slow cooling

≤ 241

1050-1140 Oil cooling

600-700 Air cooling

≤ 55

DAC45

820-870 Slow cooling

≤ 241

1060-1080 Oil cooling

580-650 Air cooling

≤ 55

YXR3

800-880 Slow cooling

≤ 241

(1)1150-1170,(2)1130-1150 Oil cooling

560-590 Air cooling

≥ 57

YXR33

800-880 Slow cooling

≤ 241

1080-1160 Oil cooling

550-600 Air cooling

≥ 56

DM

750-800 Slow cooling

≤ 241

830-880 Oil cooling

400-650 Air cooling

≤ 50





FDAC

38-42

Delivery in prehardened condition

(1) Simple shape tools (2) The others, especially needs toughness

Quenching and tempering time of YSS die steels 1.Holding time at hardening temperature (1) Preheating time First stage: 500~550°C hardening temperature holding time x 2 Second stage: 750~800°C hardening temperature holding time x 1 But preheating can be omittted when the electrical furnaces process is used or when workpieces are 50mm or under in thickness or a simple shape. (2) Holding time at hardening temperature Furnace Electrical furnace, Salt bath

Thickness(mm) Holding time(min)

≤ 15

25

50

75

100

125

150

200

300

15

25

40

50

60

65

70

80

100

Caution: The salt bath needs preheating. Set the Soaking time same as the holding time.

2.Holding time at tempering temperature Thickness (mm)

≤ 25

26-35

36-64

65-84

85-124

125-174

175-249

250-349

350-499

Holding time (h)

1

1.5

2

3

4

5

6

7

8

5

Quenched and tempered hardness curve DAC 60

DAC3 60

60

1,050°C 1,100°C

DAC55

DAC10 60 1,020°C

1,040°C 55

50

50

1,020°C

50 1000°C

30

Hardness (HRC)

Hardness (HRC)

40

1,000°C

40 Hardness (HRC)

40

950°C Hardness (HRC)

50

1,020°C

30

45

40

35

30 20

20 30

0

10

300 400 500 600 700

0

Tempering Temperature (°C)

10

400 500 550 600 650 700 Tempering Temperature (°C)

0

60

60

60

50

50

20

50

10

400 500 550 600 650 700

0

1,200°C 1,175°C 1,125°C

Tempering Temperature (°C)

DM

Hardness (HRC)

58 56

52

48

50

46

700

Tempering Temperature (°C)

1,120°C

52 50

600

500 1,140°C

54

54

550

1,160°C

58 56

44

400 500 550 600 650 700

600

60

1,150°C

500

20

YXR33

60

48

20

0

62

62

30

400 500 550 600 650 700

YXR3 60 64

30

Tempering Temperature (°C)

Tempering Temperature (°C)

40 Hardness (HRC)

30

20

0

850°C 400

100mm cube 300mm cube

300

500

550

1,070°C

1,050°C 40

950°C

Hardness (HRC)

10

60

1,130°C

Hardness (HRC)

Hardness (HRC)

Hardness (HRC)

30

DAC45

1,090°C

1,000°C

40

400 500 550 600 650 700 Tempering Temperature (°C)

MDC-K

1,050°C 40

0

Tempering Temperature (°C)

1,020°C

50

25

400 500 550 600 650 700

YEM-K

DAC40

Hardness (HRC)

HOT WORKING TOOL STEELS

20

600

650

Tempering Temperature (°C)

6

200

0 100 200 300 400 500 600700 Tempering Temperature (°C)

0

400 500 550 600 650 700 Tempering Temperature (°C)

Properties Comparison Properties

Carbide (Area ratio)

%

4 3 DAC45 2

HOT WORKING TOOL STEELS

840

800 300

400

DAC

500

600

(Tensile strength at 700°C) N/mm2

20 DAC3 40

High -temperature strength

YEM-K

1 A1 Point (°C)

YXR33

(Charpy impact value) J/cm2

60

Toughness

Guide for selecting die materials (example) Hot forging dies

YXR33 (Higher wear resistance)

For severe forging condition Warm forging, Gear forging

DAC

DAC45 (Higher resistance to progress of crack)

Precision hot forging Hot former

YEM-K

General Higher resistance to heat crack and wear (Low raising temperature by forging)

Extrusion dies

DAC General

DAC3 (Higher hardness)

Die casting dies

Higher resistance to softening by multiple nitriding

DAC40

Large die Higher resistance to deflection

DAC10

Higher resistance to deflection

DAC3 (Higher hardness)

DAC

Anti-meltdown Insert pin

YXR33

For high melting point alloy

DAC45

General

7

Precision die casting High resistance to heat crack

DAC55 DAC10

Properties Tensile strength at elevated temperature

Tempering parameter

1800 1600

YXR33

1400

500 YEM-K

1000

DAC3 800

DAC

600

YEM-K

YXR33 DAC3

400 200

DAC

0 35

40

700°C

45 50 Hardness (HRC)

55

200

19

20

30 YEM-K 20 YXR33

40

DM(42HRC)

100

DAC

45 50 Hardness (HRC)

55

DAC (44HRC) 50

0

60

0

100

200

300

400 500

600

700

Testing temperature (°C)

Hardenability

Nitriding property 1200

Half temperature time=Time required for cooling from quenching temperature to (Quenching temperature+Room temperature) /2 70

YEM-K 1000

DM (850˚C) DAC (1,025˚C)

60

YXR33

800 Hardnes (HV)

50 Relationship between diameter of round bar and half temperature time for the center part of the bar

20

Diameter of round bar (mm) Oil cooling

22

DAC3

40

10

21

Charpy impact value at elevated temperature

2U Charpy impact value (J/cm2)

2U Charpy impact value (J/cm2)

18

Tempering parameter

10

0

17

150

50

30

P=T (20+log t) /103 T:Temperature(k) t :Time(h)

60

60

0 35

400

300

Charpy impact value at room temperature

Hardness(HRC)

HOT WORKING TOOL STEELS

Hardness (HV)

Tensile Strength (N/mm2)

1200

40

YXR33 MDC-K YEM-K DAC DM

600

600°C

100 3 4

200 6 8 10

Diameter of round bar (mm) 100

DAC 600

400 DAC3

200 300 400 500 600

300 400500 600

Air cooling

20 30 40 60 80100

200

570°C X 90min Nitriding in salt bath

200 300400

Oil cooling Air cooling Half temperature time (min) 0

Relationship between half temperature time and quench hardness of hot working steels

8

0

0.05

0.1 0.15 0.2 Distance from surface (mm)

0.25

0.3

Properties 1.Coefficient of thermal expansion

[X10-6/°C]

Grade

200°C

400°C

600°C

700°C

YXR33

11.6

12.1

13.0

13.2

DAC45

10.5

12.4

13.3

13.6

DAC10

11.1

12.3

13.8

13.2

DAC

12.5

13.2

13.8

14.0

DM

12.1

13.1

13.5

13.8

HOT WORKING TOOL STEELS

2. Thermal conductivity

[W/(m·k)]

Grade

20°C

200°C

400°C

600°C

700°C

YXR33

27.2

28.1

29.3

29.7

29.7

DAC45

26.4

27.6

28.9

28.1

27.6

DAC10

32.2

31.4

30.6

29.3

28.5

DAC

30.6

30.1

29.3

29.5

28.5

DM

36.0

39.4

37.7

36.0

35.2

1.Modulus of elasticity Grade

[GPa]

20°C

200°C

400°C

600°C

DAC

206

196

178

132

DM

211

204

190

141

9

DIE STEELS FOR DIE CASTING DAC Series In compliance with changes of die casting technology

1

YSS Correlation for Diecasting Die steels

High

In compliance with diversification of diecasting technology, variety of steel grade is prepared in order to best fit for each individual application.

YXR33

For ejector pins

High temperature molten alloy High strength at high temperature

DAC10 Strength at high temperature

DIE STEELS FOR DIE CASTING / DAC Series

DAC45

DAC55

Strength toughness

Isotropy

FDAC

DAC

SKD61

Prehardened steel

E-DAC

Standard die steel

HPM7

Toughness

High

Die Steel for Diecasting Die-Kind and Features Applications Die for Aluminium/Zinc Alloy in general use

High efficiency die, Squeeze die

Steel Brand

Features

DAC

Strength at elevated temperature and toughness are well

equivalent to JIS SKD61

balanced. Good machinability and less deformation after

0.38C-5Cr-1.3Mo-1V

heat treatment.

DAC55

Superior heat crack resistance. Higher toughness enables initial hardness of dies much

5Cr-Mo-V-Ni-Co

higher.

DAC10

Higher strength at elevated temperature and good heat

5Cr-2.5Mo-V

crack resistance.

Die for high melting point aluminium

DAC45

Higher strength at elevated temperature.

alloy and copper alloy

3.5Cr-W-Mo-V

Good crack development resistance.

YXR33

Highest strength at elevated temperature.

Matrix HSS

Best erosion resistance.

FDAC

Standard hardness is 40HRC.

Precision Die Cast Die

Longer life pin, insert die parts

Die for small lot, Simple die

Simple die Core, Backblock

SKD61+S

Sulphurized DAC

Delivered prehardened.

HPM7

Prehardened to 32HRC.Good machinability & Toughness. Least difference of hardness between surface and center

Mn-Cr-Mo

of large mold.

2

Appearance of Heat Crack and Test Result Heat crack

Appearance

Cross Section

Diecast in general use On the flat surface of dies Network Temperature of molten material

DIE STEELS FOR DIE CASTING / DAC Series

0.1mm

0.1mm

Precision/Hi-Si Al-alloy Diecast On the edge of dies Crack openning Temperature of molten material 50mm

0.1mm

Diecast in SQ use At the corner of dies Stress concentration Temperature of molten material

0.4mm

Number of cycles of heat crack initiation and cross sectional appearance Test: Repetition of Heating upto 600°C by high frequency and Cooling by spray water. Specimen used is one end of dia 90mm bar.

No. of test cycle Steel Brand HRC

DAC

43

DAC

47

1000

Occurance of heat crack

DAC

51

DAC10

47

DAC55

50

DAC55

53

cycle 2000

3000

Observation of heat crack

3

Cross sectional appearance

0.5mm

Mechanical Properties Tensile Strength at elevated temperature (N/mm2) (MPa) 1,800

170

1,600

160

1,500

140

1,300

130

1,200

Quench 1,020°C x 30min Half Temperature Time 30 min. Oil Cooling

44HRC Tensile Strength

150

1,400

Tensile Strength

Tempering Hardness 50HRC

180

1,700

40HRC

120

1,100

110

1,000

100

900

90

800

80

700

70

600

60

500

50

400

40

300

30 20 100

200

300

400

500

600

700

Testing Temperature X 10min.

Tempered hardness vs Tensile Strength at elevated temperature 1400 Tensile Strenght at elevated temperature (N/mm2)

Tempered hardness vs Charpy I - Value 70

600°C

DAC55

1200

60 DAC55

DAC10

1000 800

DAC

600

2U Charpy Impact Value (J/cm2)

DIE STEELS FOR DIE CASTING / DAC Series

(kgf/mm2)

YXR33 DAC45

DAC10

400

DAC55

DAC

200

DAC10

DAC55

50

DAC

DAC DAC45

40 DAC10

30

Quench Cool Speed solid line:oil cool dashed line:half temperature time 30min

20 10

700°C 0

0 40

45

50 Hardness (HRC)

55

60

40

42

44 46 Hardness (HRC)

48

50

Physical Properties Thermal Expansion Coefficient X 10-6/ °C Thermal Conductivity W/m·K[cal/cm·s·°C]

Temperature

DAC

DAC10

DAC55

DAC45

YXR33

100°C

11.7

10.7

11.6

10.5

11.6

700°C

14.0

13.2

13.7

13.6

13.2

20°C

30.5 [0.073]

32.2 [0.077]

34.5 [0.082]

26.4 [0.063]

27.2 [0.065]

700°C

28.0 [0.067]

28.5 [0.068]

28.0 [0.067]

27.6 [0.066]

29.7 [0.071]

4

DAC

Quenched & tempered hardness 60

DAC Standard Quality for Aluminium Diecasting

50 Hardness (HRC)

DAC (Quench 1,020°C HTT 30min)

40

30

20

Features

10 500 550 600 as quenched 400 Tempering Temperature (°C)

*Good balance of both strength at elevated temperature and toughness. *Good machinability with less deformation after heat treatment.

650

700

Standard Heat Treatment Process

Applications

1,000 ~1,050°C

Quench

*General die for Aluminium Diecasting. *Die for Zinc Diecasting. *Die for low pressure casting.

Forced Air Cooling High Pressure Gas Cooling etc.

750 ~800°C

(Remarks) Both forged and cast steel available for low pressure casting die with prehardened condition of 30-40HRC.

500 ~550°C Second Pre -heating

First Pre -heating

Hardend hardness 45~48HRC general size dies. 43~46HRC big size dies.

Austeniti -zation

300 ~350°C

Quench cooling speed and Microstructure (X400) Oil cool

Air Cooling

Tempering

Pre -heating

Half Temperature Time (30min.)

To Tempering Furnace 100~150°C

550~680°C

Temper

Room Temperature

Tempering is required at least two times or more.

Tempered hardness vs Charpy I-Value (J/cm2) (kgf·m / cm2) 80 8

Half Temperature Time (60min.) Quench Temperature 1020°C Hardness 44HRC

2U Charpy I-Value

DIE STEELS FOR DIE CASTING / DAC Series

DAC is most widely used as Die for Aluminium and Zinc Diecasting. DAC is hot working tool steel with good balance of strength, toughness and heat resistance. With introduction of Isotoropy technology DAC has become tougher and more isotropic to help life of dies longer and stable.

5

70

7

60

6

50

5

40

4

30

3

20

2

10

1

0

0

1,020°C

Oil cool Half Temperature time 15min 30min 45min 60min

40

44 48 Hardness (HRC)

52

DAC55

Quenched & tempered hardness 60

DAC55 For High Performance Diecasting

1020°C

DAC55 has been developed in responding to the needs for a longer die life or a steel with good hardenablity as well as heat crack resistance and toughness for large and medium size dies.

50

Hardness(HRC)

1000°C 45

40

*Good heat crack resistance. *Higher service hardness of 50-53HRC. *Higher resistant to crack development. *Higher strength at elevated temperature. *Good hardenability.

35

30

25

Applications

400

500

as quenched

*Precision diecasting die. *Big and medium dies for diecasting. *Squeeze diecasting die.

550

600

650

700

(°C)Tempering Temp.

Recommended hardness Hardness (HRC)

Standard Heat Treatment Quench 1010-1030°C quick cool Temper 550°C-640°C Hardness 43-53 HRC

Application

50-53

Small / Squeeze Die ( Anti-Heat Crack )

46-50

General Use Die

43-46

Large Die (Priority: Toughness)

(Remarks) Recommended hardness may not apply depending on projection or casting conditions

Quench cooling speed and Microstructure (X 400)

Tempered hardness vs Charpy I-Value Charpy I-Value (kgf·m/cm2)

Half Temperature Time (15min.)

5

DAC55

4

40

DAC

3 2

20

1 0

Half Temperature Time (30min.)

46

48 50 Hardness (HRC)

Charpy I-Value (J/cm2)

6

52

Quench Cool Speed vs Charpy I-Value

Quench Temperature 1020°C Hardness 44HRC

(Test Result of 250mm Qubic Block) 50 2mmU Charpy I-Value (J/cm2) T-Direction

DIE STEELS FOR DIE CASTING / DAC Series

Features

Oil cool

Quenching temperature 1040°C

55

40

30

DAC (45HRC)

20

10

0

6

DAC55 (50HRC)

0

10

20 30 40 Half Temperature Time (min) Cooling Time (1,020°C→520°C)

50

60

DAC10

Quenched & tempered hardness 60

DAC10 For Precision Diecasting

50 Hardness (HRC)

As material of die for diecast products required higher level of surface, and heat crack resistance has been intensified. Most useful for small and medium size dies of their longer life.

30

20

*Higher strength at elevated temperature and good heat crack resistance. *Good erosion resistance.

10

400 as quenched

500

550

600

650

700

Tempering Temperature (°C)

Applications *Small / Medium size dies of which O-ring grooves require heat crack resistance. *Medium dies for products like headcover which requires good appearance. *Small dies for VTR parts or OA components which require erosion resistance.

Quench 1010-1030°C quick cool Temper 570°C-610°C Hardness 44-51 HRC

Quench cooling speed and Microstructure (X 400) Oil cool

(1020°C Quenching)

(J/cm2) (kgf·m/cm2) 80 8

2U Charpy I-Value

Standard Heat Treatment

Tempered hardness vs Charpy I-Value

Half Temperature Time (15min.)

70

7

60

6

50

5

40

4

30

3

20

2

10

1

0

0

Oil cool Half Temperature time 15min

60min 30min 45min

40 44 Hardness (HRC)

48

52

Oil Cool Test Piece Size: 10 X 10 X 55mm

Quench Cool Speed vs Charpy I-Value (1020°C Quenching)

(J/cm2) (kgf·m/cm2) 80 8

Half Temperature Time (30min.) Quench Temperature 1020°C Hardness 44HRC

2U Charpy I-Value

DIE STEELS FOR DIE CASTING / DAC Series

Features

DAC10 (Quench 1,020°C HTT 15min)

40

70

7

60

6

50

5

40

4

30

3

20

2

10

1

0

0

40HRC 44HRC 48HRC 52HRC

Oil cool

7

15

30 HTT: min.

45

60

DAC45

Quenched & tempered hardness 60

DAC45 For Diecasting Al-Alloy containing high Silicon Hardness (HRC)

50

Exclusively developed for dies used in elevated temperature casting of 750°C molten steel. Superb erosion resistance.

30 DAC45 Quench 1,070°C Oil Cooling

20

*Exceptional high strength at elevated temperature. *Higher resistant to crack development.

10

Applications

as quenched

500

550

600

650

700

Standard Heat Treatment Process 1,060 ~1,070°C

Quench

Standard Heat Treatment

750 ~800°C

Quench 1060-1070°C oil cool Temper 570°C-610°C Hardness 47-51 HRC

Oil cool

500 ~550°C First Pre -heating

Quench temperature and Microstructure (X 400) 1060°C

400

Tempering Temp. (°C)

*Die for High Silicon Aluminium Diecasting like ADC14. *Die for Copper Alloy Diecasting. *Erosion resistant pin, insert die parts.

Second Pre -heating

Austeniti -zation

1080°C

100~150°C To Tempering Furnace

570~640°C

Temper 300 ~350°C

Air Cooling

Pre -heating

Tempering

Room Temperature

Tempering is requuired at least two times or more.

Overheat 1100°C

Softening Resistance 50

DAC DAC45 45 650°C 40

Hardness (HRC)

DIE STEELS FOR DIE CASTING / DAC Series

Features

40

35 700°C 30

25

20

8

0

1

2 4 Keeping Time (h)

8

YXR33

Quenched & tempered hardness 62 Quenching Temperature 1,160°C

YXR33 For High quality Insert Pin

60

YXR33 is a HSS with higher toughness which solved breakage problem often existed in SKH51. Fitted for insert pin or other inserts exposed to critical wear due to erosion.

58 1,140°C

Hardness (HRC)

56

DIE STEELS FOR DIE CASTING / DAC Series

Features *Highest strength at elevated temperature among HSS and Alloy Tool Steel. *Toughness is more than 5 times as big as SKH51. *Excellent nitridability.

1,120°C 54 1,080°C 52

50

Applications 48

*Erosion resistant insert pin. *Insert die parts.

46

Standard Heat Treatment Quench 1080-1140°C oil cool Temper 550°C-600°C Hardness 52-58 HRC

0

500

550

600

650

Tempering Temp. (°C) X 1h

Specimen after Meltdown Damage Test Microstructure as quenched & tempered (X 400)

Weight loss 46.8%

1140°C

DAC (48HRC)

14.8% DAC (48HRC) Nitriding

0.8% YXR33 (52HRC) Nitriding

Meltdown Damage Test (Specimen and Testing Condition) 90rpm Test 2h Heater

Molten Al-Alloy 700: 90mm

10mm 10mm

Specimen

9

FDAC/HPM7 Mechanical Properties (Reference)

Prehardened free machining die steel

Hardness

0.2% Yielding Tensile

(HRC)

FDAC FDAC is based on DAC for main components with addition of Sulphur for machinability. As delivered prehardened to 38-42HRC, direct cavity making is possible.

Elongation

Reduction

Strength

Strength

of Area

(MPa)

(MPa)

(%)

(%)

DAC

40

1070

1250

12

58

FDAC

40

1060

1240

11

20

HPM7

32

860

980

20

55

DIE STEELS FOR DIE CASTING / DAC Series

HPM7 HPM is prehardened to 29-33HRC and has good machinability.

Charpy I - Value (Reference) (HRC)

Longitudinal direction (J/cm2)

Transverse direction (J/cm2)

DAC

40

58

39

FDAC

40

19

10

HPM7

32

67

61

Hardness

Features *Good machinability. *As delivered prehardened, no futher heat treatment is necessary. →Possible to reduce manufacturing time and total cost.

Size of Raw Material: 280 X 640 Position of Specimen: w/2 X t/4

Applications Die for small lot , simple die, plain die, holding lock. FDAC• • • priority strength. HPM7• • • priority & toughness machinability.

Machinability

Drilling

FDAC (39HRC) DAC (38HRC) Face milling

0

1

2

3

4

5

6

7

8

Index of tool life (DAC (38HRC)=1)

Cutting condition Face milling

Drilling

Cutter

f63

Tool

HSS Co φ4

Insert

Coated cemented carbide

Cutting speed

20m/min

Number of inserts

1

Feed

0.1mm/rev

Cutting speed

130m/min

Depth

40mm (Blind)

Feed

0.15mm/Tooth

Coolant

Water-Soluble

Depth

0.5mm

Life

Number of cutting hole

Coolant

dry

Life

VB=0.3mm

10

Machinability

Comparison of machinability by Endmill machining

Machinability order DAC>DAC10>DAC55>DAC45

80 60 40 20

Annealed 0

DAC

DAC10

48HRC

DAC55

DAC45

Comparison of machinability by Facemill machining

Face mill One insert as for test purpose Insert: Cemented Carbide+Coating (TiN) Depth of cut

6000 Cutted Volume to life (cc)

DIE STEELS FOR DIE CASTING / DAC Series

Ratio of Machirability (%)

100

5000 4000 3000 2000 1000

DAC

0

80

DAC55

120

160 Cutting Speed (m/min)

200

Cutting condition by Endmill (Reference) DAC10

DAC Tool Material

Powder HSS

Annealed condition

43HRC

V=25

V=20

f=0.07

f=0.05

48HRC n. a.

Annealed condition V=15 f=0.07

48HRC n. a.

DAC55 Annealed condition V=15 f=0.07 V=20

48HRC

51HRC

n. a.

n. a.

n. a.

n. a.

V=30

V=25

f=0.07

f=0.05

Cemented Carbide+Coating

V=45

V=35

V=25

V=35

V=15

V=35

V=17

V=15

Standard edge

f=0.05

f=0.03

f=0.03

f=0.05

f=0.03

f=0.05

f=0.03

f=0.03

Cemented Carbide+Coating

V=50

V=40

V=30

V=50

V=25

V=50

V=30

V=25

Hi-speed edge

f=0.08

f=0.05

f=0.05

f=0.08

f=0.05

f=0.08

f=0.05

f=0.05

Powder HSS+Coating

n. a.

11

V=20 f=0.07

n. a.

f=0.07

Repair Welding Followings show standard repair welding method in build-up welding due to design change or repair welding due to heat crack. Material involved : DAC, DAC55, DAC10, DAC45, FDAC, E-DAC. State of Die

Welding

Welding

Welding

Rod

Method

Condition

DIE STEELS FOR DIE CASTING / DAC Series

Welding

Annealed State

350~ 400°C

300~ 400°C

DAC or same steel Welding bar 1.6~4.0φ

TIG

680~ 730°C

Furnance Cooling or Ash Cooling

250: Above

After-heating

Pre-heating

100~ 150°C Anneal 2 times in case of Large block.

Current 80~200A Flux of Ar gas 8-15R/min

Hardened State

Temp. between weldlayers

Welding Process Chart

Welding

YAG

300~ 400°C

350~ 400°C

After-heating Pre-heating 100~ 150°C

below Tempering Temperature of Die Air Cooling

RT ~100°C

Remarks 1. YAG is a brand name of Hitachi Maraging Steel used for various applications including high grade welding rod. Using YAG welding rod remarkably decreases such welding defects as "bead crack" or "pin holes". 2. TIG Welding Method (Tangsten Inert Gas Welding Method) is to make arc between tangsten electrode covered by argon gas and objects to be welded, and then wire is inserted into the heat pool generated by the arc. 3. Use lower current and finer welding wire in order to get better efficiency of welding metal. In order to prevent crater cracks, avoid an overlap of the crater of backward pass on the crater of foregoing pass. To avoid an overheat of mother material, conduct an interrupted welding with short bead. 4. Keeping time of Temper and Anneal after welding should be 1h/25mm in thickness. 5. A careful attention is to be paid of crack during grinding.

12

250: Above

Actual Performance by Customers

DIE STEELS FOR DIE CASTING / DAC Series

Diecast Products Brand

Machine Capa (die size mm)

Comparision of Actural Performance by Customers Current

Effect

Application

Autoparts surface priority

800ton 120X210X300

DAC (44HRC) 37K shot 1st heat crack

DAC (48HRC) 50K shot 1st heat crack

1.35 times

OA Components (precision die)

250 ton 80X200X300

DAC15K shot 1st heat crack 30K shot repair. 80K shot scrap

DAC10 24K shot 1st heat crack. No grinding repair. 120K shot scrap

1.6 times min.

OA Components (precision die)

650 ton 90X215X380

DAC 1K shot 1st bite 30K shot scrap

DAC10 10K shot no bite

3 times min

Autoparts surface priority

2000 ton

DAC (47HRC) 60K shot heat crack

100K shot still on service

1.6times min.

Autoparts

2500 ton

DAC (43HRC) heat crack

DAC55 (48HRC) later heat crack

4 times

Autoparts (thin insert)

n.a.

DAC 20K shot breakage

DAC55 40K shot and more

2 times

Wheel

1800 ton

DAC/DAC4 heat crack

2 times shot of DAC/DAC4 before crack

2 times

P/Computer Case (Mg)

n.a.

DAC 5K shot heat crack

DAC55 25K shot no repair

5 times min

High melting point Al-alloy autoparts

320 ton 90X200X300

DAC 5K shot 1st heat crack

DAC45 10K shot 1st heat crack but still in 2 times service

High melting point Al-alloy autoparts

Insert

DAC (52HRC) 3.5K shot meltdown

DAC45 (52HRC) 13K shot meltdown

4 times

Autoparts

Insert Pin

DAC 3K shot meltdown & galling

YXR33 10K shot still on service

3 times

High melting point Al-alloy autoparts

Insert Pin

SKH51 (60HRC) 2K shot breakage

YXR33 (54HRC)+TiN 20K shot meltdown

10 times

13

PLASTIC MOLD STEELS HPM Series

In compliance with advanced plastic molding technology YSS plastic mold steels "HPM" series are increasing popularity in compliance with advanced plastic molding technology. "HPM" series are fulfilling demands of plastic industry for molds that provide crepe-and mirror-finishability and mold durability for corrosive gas generating and reinforced resins.

1

Group

Mold Material and Application Hardness Grade Employed (HRC)

Material Type

Application Example

HPM7

P20 improved

Mold required good weldability & machinability (Autoparts, Home electronics, House eguipment)

HPM38

420 improved

Flame retardant resin, Transparent parts, Rubber

HPM77

420 improved & resulpherized

(Round Bar) 38~42 (Flat Bar) 33~37

PSL

630 improved

37~42

CENA1

Cr contained NiAl precipitation grade

37~41

HPM1

P21 improved & resulpherized

Mold for general use (Home electronics etc), Plate & holder

38~42

FDAC

H13 improved & resulpherized

Engineering resin, Slide core

HPM38

420 improved

Mold for Anti-corrosion / Mirror polish (Floppy, Casette, Medical instruments, Food container, etc)

HPM38S

420 improved

Mold for super mirror polish (Optical disc / Lense)

HPM31

A2 improved

Wear resistant mold for engineering resin (Gear, Connector, IC)

YXR33

Matrix HSS

Mold required high toughness & high hardness (Core pin, Thin wall)

ZCD-M

D2 improved

HAP10

P/M HSS

ZDP4

P/M Cold Die Steel

40~45

HPM75

High hardness, nonmagnetic, resulphurized

52~57

YAG

Maraging Steel

Prehardened

Corrosion resistant mold plates, Rubber mold

Mold for polyvinyl chloride, Frothy resin, Rubber Rust resistant mold with sensitive surface as mirror polishing, creping, EDM (OA electronics, Transparent case etc)

For Quench and Temper

50~55

For Aging

PLASTIC MOLD STEELS / HPM Series

29~33

56~60

60~63

IC mold

Reinforced engineering resin, IC mold

60~65 Reinforced and flame retardant engineering resin, IC mold, Slide parts, Cutter required exceptional wear resistance Molding in magnetic field (Plastic magnet) Mold required exceptional toughness (Core pin,Thin wall), Super mirror polish (Optical lense)

2

Sequence by Technical Needs SKD11 (58HRC)

Strength

Strength Inner Hardness Machinability

HPM7

HPM38

(29-33HRC)

HPM77

SUS420J2 (53HRC)

High Hardness High Toughness Surface Texture

Mirror Polishability

HPM31

Weldability Mirror Finishability

(58HRC)

HPM38

Wear Resistivity Toughness

(29-33HRC)

PLASTIC MOLD STEELS / HPM Series

SKD61

Toughness Precis H/T Surface Texture

SCM(28HRC)

(53HRC)

YXR33

Corrosion Resistivity

Super Mirror Polishability

(58HRC)

HAP5R

Strength

(58HRC)

FDAC

HPM1

PSL

(38-42HRC)

(37-41HRC)

(33-37, 38-42HRC)

Wear Resistivity

Corrosion Resistivity

Wear Resistivity

S55C(13HRC)

Wear Resistivity

Corrosion Resistivity

(64HRC)

(62HRC)

HPM38S (53HRC) Higher Toughness Super Mirror Polishability

ZDP4

HAP10

Mirror Polishability EDM Finishability Creping Texture Rust Resistance Machinability

Corrosion and Wear Resistivity

Wear Resistivity

YAG

CENA1

HAP72

(37-42HRC)

(68HRC)

General Mold (Prehardened Steel)

(54HRC)

Precise Mold (Steel for Hardening)

Properties Comparison Table Material

Machinability

Heat Mirror EDM/Creping Weldability deformation polishability texture

Rust resistance

Wear resistance

Toughness

Cost

HPM7

4



3

3

5

2

2

4

4

HPM38

3

4

5

4

3

4

3

3

2

HPM77

4



2

2

3

4

2

3

3

PSL

2



4

3

5

5

2

4

2

CENA1

4



5

4

4

3

2

3

3

HPM1

4



3

3

3

2

2

2

3

FDAC

3



2

2

3

3

3

3

3

HPM38S

3

4

5

5

3

4

3

3

1

HPM31

3

4

5

4

2

3

4

3

2

YXR33

3

3

5

4

3

3

4

4

2

ZCD-M

2

3

5

2

1

4

4

2

2

HAP10

2

3

4

3

1

2

5

2

1

ZDP4

1

3

4

4

1

4

5

2

1

HPM75

1

3

2

2

3

3

3

3

2

YAG

2

4

5

5

5

3

3

5

1

S55C

5



3

2

3

1

1

3

5

SCM440

3



3

2

3

2

1

3

4

Ratings: 5-Best 3-Ordinary 2,1-Poor

(Remarks) Please refer above as general concept.

3

Properties Comparison Machinability

Grade S55C

13

SCM440

28

HPM7

32

HPM38

32

PSL

35

CENA1

40

HPM1

40

FDAC

40

SKD11

Annealed

HPM31

Annealed

10

Polishing Property (Schematic Diagram)

20

30

40

HPM31

60

YAG HPM38

50

Hardness (HRC)

PLASTIC MOLD STEELS / HPM Series

Drilling Tool: SKH51ø10 Feed: 0.15mm / rev Depth: 30mm (brind hole)Dry

Better

Cutting Speed (Tool Life: Cutting Length 1m)

Hardness HRC

HPM1

40

HPM38S

CENA1

HPM7

30

20

10

Super mirror finish

S55C General products

2,000

4,000

6,000

Optical disc Optical lense

Transparent products

8,000

10,000

12,000

14,000 Better

Mirror Polishability (Grain Mesh)

Corrosion Resistance (5%Sulfuric Acid Solution)

Grade

Weight Loss by Corrosion (mg/cm2 • h)

Better 5

PSL HPM38 SUS440C SKD11 HPM31 CENA1 HPM1 SCM440

4

10

15

20

Properties Comparison Wear Resistance

PLASTIC MOLD STEELS / HPM Series

Ohgoshi Wear Test Work Material SMC415 Load 6.8kg Total Friction Length 400m Friction Speed 0.78m/sec

Grade

Hardness HRC

SKD12

59

SKD11

60

HPM31

59

ZDP4

65

SUS440C

57

SKH51

63

HAP10

64

Wear Ratio (mm3/mm2 • mm) x 10-7

Mechanical Properties Grade

0.5

Better

Hardness HRC

1.0

Tensile

0.2%Yield

Strength

Strength

N/mm2

N/mm2

%

Elongation

Reduction of Area %

HPM7

32

975

854

20

55

HPM38

52

1,912

1,618

13

35

HPM77

32

990

843

16

41

PSL

39

1,167

1,098

11

34

CENA1

40

HPM1

40

1,225

1,150

15

50

L

1,225

1,029

18

40

T

1,216

1,010

10

25

HPM75

42

1,304

1,108

11

28

YAG

53

2,010

1,912

10

48

Physical Properties Grade

Thermal Expantion Coef. ( x 10-6 °C)

Thermal Conductivity (W/m • K)

100°C

200°C

300°C

400°C

20°C

100°C

200°C

300°C

400°C

HPM7

11.8

12.2

13.0

13.4

34.3

37.7

39.8

40.6

40.6

HPM2

11.5

11.9

12.5

12.9

37.2

37.6

38.0

39.3

38.0

HPM38

11.5

11.9

12.3

12.5

25.1

HPM77

10.7

11.1

PSL

10.6

11.1

11.9

CENA1

11.0

11.4

HPM1

11.4

HPM31

27.2

27.6

17.9

18.8

20.9

12.1

16.3

17.1

18.8

12.0

12.5

28.6

28.3

28.8

30.1

11.8

12.3

11.8

32.6

33.0

33.4

34.7

11.9

12.3

12.6

12.7

28.4

HAP10

10.6

10.8

11.1

11.4

19.2

HPM75

16.9

17.6

17.0

YAG

10.8

5

21.3

28.8 20.0

20.9

34.7 28.3

21.3

22.5

15.8

17.9

21.3

20.9

25.5

27.6

Resin Types and Grade Selection Required Life and Grade Recommended Resin

General

Engineering Resin Thermo

PLASTIC MOLD STEELS / HPM Series

-plastic

Required Properties for Mold

SHORT >10 milliom

Machinability

HPM7

Wear Resistivity

HPM7 FDAC

Reinforced High Wear Resistivity

CENA1 HPM1

Flame Retardant

Corrosion Resistivity

Transparent

Mirror Polishability

eneral

Wear Resistivity

set Reinforced High Wear Resistivity

HPM7 HPM2

HPM7+ Nitriding

CENA1 FDAC

Nitriding, + Plating

HPM38

HPM38

CENA1

PSL

CENA1

CENA1

HPM38

HPM38

CENA1 Thermo-

MEDIUM > 50 milliom

HPM1, 50 + Plating

FDAC

FDAC

FDAC

General Resin

: PS, PE, PP, AS, ABS etc.

Engineering Resin

: PC, PPE, PA, POM, PBT, PET etc.

+Nitriding

Advanced Engineering Resin : PPS, PI, PES, PEEK etc.

6

CENA1 HPM1, 50 FDAC CENA1 FDAC

+ Nitriding

HPM31

HPM38

HPM38

MASS PRODUCTION >100 milliom CENA1 FDAC

+ Nitriding

HPM38 HPM31 ZDP4 HAP10

HPM38

HPM38 ZDP282

CENA1

HPM1

CENA1

LONG >100 milliom

HPM31

HPM31

HPM31

HPM31

HAP10 ZDP4

40HRC Prehardened Grade

CENA1

Prehardened: 37~ 42HRC Precipitation Hardening, Rust-Resisting Grade for Precise Mold

PLASTIC MOLD STEELS / HPM Series

CENA1 is new concept grade breaking through with rust resistivity and excellent machinability. CENA1 is manufactured by consumable electrode remelting method, having exceptional high purity and suit for critical surface finish.

Mobile Telephone

Features

• No heat treatment is necessary. Uniform hardness • • • • •

distribution. (37~42HRC) Higher rust resistivity compared with P21 type grade. Excellent machinability makes machined surface better. Excellent mirror polishability, crepe- and EDM finishability. Good weldability with least hardness elevation. Good nitrinding hardenability and can be used for wear resisting application.

Video Camera

Application

• Critical surface finish mold for transparent parts, etc. • Engineering resin products.

Creping Sample

Non-glare Treatment Sample

EDM Sample CENA1 100X100X50 (mm)

7

40HRC Prehardened Grade

HPM1

Prehardened: 37~41HRC Free Machining Precipitation Hardening Grade for Precise Mold

HPM1 is free machining plastic mold steel prehardened to 40HRC . With superb machinability, HPM1 is fitted for genaral applications.

• No heat treatment is necessary. (37~41HRC) • Excellent machinability among 40HRC prehardened •

Personal Computer

grades. Uniform hardness even in large crosssection and less wear of parting.

400

Application Hardness (HV)

• General plastic products. • Home electronics, auto parts. • Daily goods for mass production. • Precision mold for rubber. • High hardness die plate, holders.

385HV

350

EDM Condition Electrode: Cu Voltage : 90V Current : 3A

300

~ ~ 0.05

0.1

0.15

0.2

Distance fromSurface (mm)

FDAC

Hardness Distribution of EDMachined Surface in Depth (HPM1)

Prehardened: 38~42HRC Free Machining Hot Working Die Steel

50

Features

CENA1, HPM1, FDAC

• No heat treatment is necessary. (38~42HRC) • High wear resistance and toughness. • High abrasion resistance. • High hardness obtained by nitriding.

Hardness (HRC)

PLASTIC MOLD STEELS / HPM Series

Features

Application

• Slide parts, Pin. • Engineering resin products.

40

HPM7,HPM2 30

SCM440 20

S50C 150

100

50

0

50

100

150

Distance from Center (mm)

Cross Section Hardness Distribution (300mm Square Size)

8

32HRC Prehardened Grade

HPM7

Prehardened: 29~33HRC For Medium and Large Mold for General Application

Inner Panel

Features

Tail Lamp

• Uniform hardness distribution even in large crosssection. • • • • • •

(29-33HRC) Machinability is better than P20 or free machining carbon steel. Excellent weldability with least hardness elevation. Good mirror polishability. Less streak texture and least hardness elevation on EDM surface makes finishing easier. Excellent toughness. Excellent nitriding property.

Endmill: Co-HSSø3 V=22.5m/min f=0.0552mm/Tooth a=2wX10H Wet

0.4

Tool Wear (mm)

PLASTIC MOLD STEELS / HPM Series

HPM7 is plastic mold steel prehardened to 29~33HRC fitted for medium and large size mold, having good machinability and weldability. In addition, it has good mirror polishability and EDMachinability to make itself one of the best steel among P20 improved grades.

Application

SCM440

0.3

HPM1 0.2

HPM7 0.0

• Auto parts ex.Headlight lense, Taillamp, Inner panel • •

etc. Home electronics, House equipment ex. TV cabinet, Air conditioner housing etc. Others large daily goods, Large container, Pipe, Rubber.

0

2

4

6

8

Cutting Length (m) Machinability Comparison HPM7

SCM440

No crack

Crack has occurred

y-groove Weld Crack Test JIS Z 3158 TIG Welding No pre-heating / No post-heating

9

10

Prehardened Stainless Grade Prehardened: 29~33HRC Hardenable to: 50~55HRC For Anti-Corrosion and Mirror Polish Mold

Compact Disc

HPM38 is Mo contained 13Cr martensitic stainless steel prehardened to 29-33HRC, manufactured by consumable electrode remelting method, further hardenable to 5055HRC. It is fitted for molds which require corrosion resistance and superb mirror polishability. In addition, it suits for precise heat treatment. Excellent corrosion resistance also makes mold storage easier.

Features

Application

• Transparent items: Lense, Container for cosmetics, etc. • Flame retardant resin products: Home electronics, OA equipment.

• For saving plating: Food container,Medical instruments. Heat Treatment

• Quenching: 1,000~1,050˚C Air Cooling. • Tempering: 200~500˚C Air Cooling.

Dimensional Distortion (%)



mold. As HPM38 is supplied as prehardened condition, it can be used without further heat treatment also.

Food Container

Hardness (HRC)

• Excellent mirror polishability. • Better corrosion-resistivity than 420. • Chromium plating is not necessary. • Least heat treatment deformation, best fitted for precise

Size: 65TX100WX150L Quench: 1,030˚C (VQ) N2gas Cooling

0.10

Width

0.05

-0.05

56 54 52 50 48 as Quench

HPM38S

Prehardened: 29~33HRC Hardenable to: 50~55HRC For Super Mirror Polish Mold

Features

• Superior mirror polishability to below 0.01µ m surface roughness.

• Other features are same as HPM38. • CD, DVD, MO, and optical lense.

200

300

400

500

Tempering Temperature (°C) Heat Treatment Properties of HPM38

100

50

SUS420J2

HPM38

HPM38S

Purity of HPM38S

10

Length

0

Nonmetallic Inclusion Quantity (Index Number)

PLASTIC MOLD STEELS / HPM Series

HPM38

600

Prehardened Stainless Grade

PSL

Prehardened: 33~37HRC (Flat bar) 38~42HRC (Round bar) For Higher Grade Anti-Corrosion Mold

PSL is precipitation hardening stainless steel which shows superior corrosion resistance as used for corrosive gas yielding resins or resins with flame retardant additives without plating.

Features Plating is not needed.

• Least hardness elevation on EDM or welded surface and easier finishing jobs.

PVC Extruded Products

Application

Weight Loss by Corrosion (%)

PLASTIC MOLD STEELS / HPM Series

• Best corrosion resistance among plastic mold steels.

• Polyvinyl chloride: Pipe fittings, Pipe, Sash etc. • Resins with flame retardant additives • Precision mold for rubber

HPM77

Prehardened : 29~33HRC Free Machining Martensitic Stainless Grade for Mold Base

SKD11(58HRC)

2.0

SCM440 Cr plating (Test Condition) Solution: 10%HCL Temp: 40°C

1.5 1.0

SUS420J2(30HRC)

0.0 0 0

SUS304 PSL(40HRC) 10

20

30

40

50

Dipping Time (hr) Corrosion Resistivity Comparison

Features

• Good corrosion resistance and well fitted for rust • •

protection of water cooling holes or surface of mold base. Excellent machinability Prehardened and good mechanical properties

Water level

Application

• Holder for compact disc mold or lense mold. • Holder for food or medical container mold and precise • •

engineering resin mold. Mold for rubber Anti-corrosive support tools

S55C

HPM77

Rust after 1month dipping in water

11

High Wear Resistance Grade

HPM31

Hardenable to: 55~60HRC High Wear Resistant Grade for Mass Production

Features

• High wear resistance as same as D2. • Much better machinability and grindability than D2. • Least heat treatment deformation, best fitted for precise • •

Engineering Resin Gear

mold. Good mirror polishability, crepe- and EDM finishability High hardness and toughness.

Application

• Engineering resin products and thermosetting resin products.

• Precise mold: IC mold, Connector, Watch parts, Camera

IC Mold

parts.

Dimensional Distortion (%)

Heat Treatment

• Quenching: 1,000~1,050°C Air Cooling. • Tempering: 200~550°C Air Cooling.

Hardness (HRC)

PLASTIC MOLD STEELS / HPM Series

HPM31 is wear resistant plastic mold steel with fine carbide uniformly distributed by means of appropriate alloy design and consumable electrode remelting process. Least heat treatment distortion, it suits for precise heat treatment.

0.15

Size: 16TX46WX60L Quench: 1,030°C (VQ) N2gasCooling

Thickness Width Length

0.05 0 -0.05

62 60 58 56 54 as Quench 200

300

400

500

Tempering Temperature (°C) Heat Treatment Properties of HPM31

12

600

Aging Grade

YAG

Hardenable to: 50~57HRC Super High Toughness Maraging Steel

As YAG is delivered as solution heat treated condition, you are advised to conduct aging at 480-520°C in order to get hardness between 50-57HRC after engraving cavity.

Ejector pin

• Superior toughness and mechanical properties under • •

high hardness and best fitted against breakage. Super mirror polishability. Hardness about 55HRC is obtainable by aging at 480°C with least distortion.

Lense

Application

• Optical lense. • Thin core pin. • Ejector pin, either of smaller dia-meter or of longer

3000

YAG

length.

HPM75

Notch Strength (N/mm2)

PLASTIC MOLD STEELS / HPM Series

Features

Hardenable to: 40~45HRC Non-Magnetic High Hardness Free Machining Plastic Mold Steel

2000

SKD61 1000

Features

SCM440

• Permeability (µ) is 1.01, equally non-magnetic as 304. • 40-45HRC is obtainable by aging of 700°CX5h and has higher wear resistance.

• Good nitriding properties.

0 20

30

40

50

Relationship between Hardness and Notched Tensile Strength

Remarks: Slower machining recommended as it is easily hardened by machining.

Application

• Plastic magnet. • Wear resistant, non-magnetic supportive tools.

Plastic Magnet

13

60

Hardness (HRC)

Higher Grade Polishing Method of Plastic Mold Polish procedure Example

PLASTIC MOLD STEELS / HPM Series

Polish by oil grinding stone (use kerosene) #180 #240 #320 #400 #600 #800 Polish by oil sand paper (use kerosene) #600 #800 #1000 #1200 #1500 Finish Polishing by diamond compound (use felt cloth) #1200 #1800 #3000 #8000

Important points of polishing

Remarks:

1. Each procedure is to be strictly kept. 2. When changing from one number to

A. For superior polishing use diamondcompound. Don't use alumina nor chromium-oxide compound.

another, check if there are remained scrach by changing polishing direction. (move 45-90 degrees) 3. When changing numbers, wash and remove last polishing grains completely. 4. Polishing by diamond compound needs to be done in short times. Excessive polish can produce pinholes or orange peel. 5. Don't use alumina and chromium oxide for finishing as the polish capabilities are lower than diamond. 6. During long interruption, the object must be protected from the rust.

Diamond Compound Finish

Aluminium Oxide Finish Not Good

Chromium Oxide Finish Not Good

B. Lord for polishing should be kept lowest possible. C. Foregoing polish should be done prudently. D. Rust proof measures must be taken in any interruption of jobs.

Seam and pinhole texture at crossing by less foregoing polish

Scratch remains due to overload.

Pinhole texture by inapropriate rust proof.

Welding of Plastic Mold Attentive points

≥ 5C

1.Preparations before welding

≥ 5R

A. Form of location to get welded should be made smooth as Figure 1. B. Cracks and treated surface (nitrided or plated) must be eliminated. C. Oil, dust, moisture and scale must be removed thoroughly.

Corner Build Up

Edge Build Up W 45˚

R R>D

A. Welding rod of similar composition as mold is to be used so that welding may not bring about unevenness of mirror finish or creping surface. When the mold is made from HPM1, use welding rod made from HPM1-W. Likewise, in case fo TIG welding there are T-HTM-31 and T-HTM38 in the market for welding for mold made from HPM31 and HPM38. B. In case of using coated electrode, mold should be dried by heating to 250-300˚C. C. For cavity welding, TIG welding should be applied. (TIG: Tungsten Inert Gas) Welding Rod Grade

CENA1

Welding

TIG

Rod

CENA1-W

Groove/Hole Build Up

Figure 1. Standing shapes for build up welding

3.Welding A. Figure 2 shows example of actual welding jobs of representative grades. B. Tempering should be conducted soon after welding in case of prehardened steel or hardened and tempered steel according to Figure 2. Tempering is effective to protect mold from crack and to stabilize mirror finish and creped surface by having uniform hardness and structure. Heat Cycle

Condition Welding

TIG Welding • Rod 2.4 3.2

Current • • • • • • 80~160A • • • • • • 110~200A

Post-heat 200~400°C

Pre-heat 200~400°C

HPM7-W

Shielded Metal Ark

TH50

HPM7

Metal Ark Welding •Shielded Current Rod 3.2 4.0

• • • • • • 90~120A • • • • • • 130~160A

Welding Pre-heat 100~150°C

1hr/ 25mm Air Cooling Tempering 500~600°C

Post-heat 200~300°C

1hr/ 25mm Cool Slowly

Figure2. Welding procedure

14

Tempering 450~550°C

Cool Slowly

Flow Rate 10~15 /min TIG

W>4D

D

2.Welding rod

Air Cooling

PLASTIC MOLD STEELS

CENA1

Innovated for 21century global standard grade. •Solution for Mold Rust Problem •40HRC Prehardened Grade with Excellent Machinability •Excellent Polishability, Crepability and EDMachinability •Most Suitable for Weldless Molds

1

Features •Solution for Mold Rust Problem •40HRC Prehardened Grade with Excellent Machinability •Excellent Polishability, Crepability and EDM Machinability •Most Suitable for Weldless Molds

CENA1, new concept tool steel for injection mold, breaks through with excellent machinability and rust resistivity. Manufactured by consumable electrode remelting process, CENA1 has low non-metallic inclusion content and excellent mirror polishability. CENA1 is delivered in 40HRC prehardened condition.

HPM38 32HRC prehardened 420 improved

Rust Resistivity

PLASTIC MOLD STEELS / CENA1

Characteristics

Patented Steel

CENA1

P21 improved

40HRC prehardened

Machinability

•Properties Comparison Grade

Hardness (HRC)

CENA1

37-42

P21 improved

37-41

P21 improved and sulfulized

37-41

P20 improved

29-33

P420 improved

29-33

excellent Rust Resistivity

Machinability

2

Mirror Polishability

Crepability

poor EDM Machinability

Application and Actual Performance

•Application

•Molds for which temperature control is required

(Weldless molds, etc.) Mold reguiring sensitive surface as mirror polishing, creping and EDM OA equipment, Communication equipment (ex.Mobile telephone, Video camera, CD case) Home Electronics (ex.Cleaner, Air conditioner) Auto parts (ex.Tail lamp, Inner panel, Transparent cover) Cosmetics case, bottle General resin



PLASTIC MOLD STEELS / CENA1



•Actual performance Example Rust Resistivity Application Mobile Phone

CD Tray

Comparison of Actual Performance with Conventional Grade by Customers Less rust and deformation during EDM. Less rust and corrosion by resins during molding. (Mold durability increase more than 4 times compared with conventional grade.) Resistant to corrosive gas generated by ABS resin, mold maintainance frequency decreased drastically.

Electronics Parts

Least rusting during WEDM for 1 week. Rust removing process becomes unnecessary.

Mechanical Parts

Resistant to corrosive gas generated by advanced engineering resins. Mold durability is improved.

Machining Air Conditioner Filter Acrylic Lense TV Speaker Auto Head-light Lense

Less tool wear during precise rib machining and better surface obtained. Nitrided hardness 70HRC is effective to prevent mold depression by resin burr. Carbide endmill tool life is doubled. Easy to mirror polish EDM surface. Many small pins ware EDMachined. Better EDM surface has been obtained compared with conventional grade. Good machinability in ball endmilling. Smooth surface machined with 0.4R ball endmill makes polishing easy.

3

Rust Resistivity CENA1 has improved rust resistivity compared with conventional 40HRC prehardened grade. of corrosion problem •Improvement on mold surface by resins. rust formation at cooling •Decreased water hole makes cooling effect

Rust Resistivity of Polished Surface

stable. Fewer rust problem in storage, transportadion, or usage of mold Much less rust formation on WEDM surface

PLASTIC MOLD STEELS / CENA1

• •

P21 improved

CENA1

Dip in Water for 24Hrs

•Actual Performance Example of Rust Decreasing at Cooling Water Grooves of PET Parison Mold

Cooling Water Grooves

Injection Mold Product

CENA1

No plating

P21 improved and sulfurized+Cr plating

CENA1 Molding Result CENA1 Surface Treatment

No Plating

Mold after 2 Months Use

Rust is removed easily by wiping.

P21 improved and sulfurized Cr Plating

Cr Plating came off and material was rusted deeply.

Photographs show water cooling grooves of the molds after 2 months use. (3 cavities…CENA1, 3 cavities… P21 improved and sulfurized + Cr Plating, Total 6 cavities with one molding machine)

4

Rust Resistivity CENA1 increases mold durability against corrosion by gas generated from resin. Gas generated from resin often becomes high temperature by injection pressure and corrode the mold. It brings cloudiness of mirror surface and burr of injected parts. CENA1 improves above gas-corrosion resistance by alloy combination.

Resin

CENA1

PLASTIC MOLD STEELS / CENA1

Figure

P21 improved

5mm

Acceleration gas-corrosion tests by a mold that is POM

made to shut gas intentionally. Observation results of the mold surface after 3000 shots of POM and ABS flame retardant grade.

Change on surface of specimens after injection molding tests

5µm

ABS flameretardnt grade 5mm

• CENA1 and Weldless Molds CENA1 is most suitable for weldless molds for which temperature control is required, bucause surface condition of heating and cooling holes comes to be less corrosive and more stable. CENA1 is widely used for the products such as PDP (Plasma display panel) and video cameras for better surface condition is indispensable. Weldless Molds

5

Machinability Excellent machinability of CENA1 doubles tool life compared with conventional 40HRC grade tool steel in endmilling. • CENA1 can promote cutting efficiency • CENA1 can decrease tool-change frequency drastically. • Smooth cut surface of CENA1 makes afterpolishing easier. 1.VT Curve HSS-Co 2NKR ø10

Machine: Matsuura MC-800VF Side Surface Cutting, Wet (Soluble), Downcut, Overhang: 35mm Tool Life Definition: Tool Wear 0.3mm

Cutting Speed Up

35

Cutting Verocity(m/min)

30 25 20

Doubled Tool Life

15 CENA1

10

P21 improved

5

0

0

100

200

300

400

Cutting Verocity Feed Cutting Depth Cutting Efficiency (mm/teeth) (mm) (cm3/min) (m/min) 15 0.055 15Hx1W 0.80 22.5 0.055 15Hx1W 1.19 30 0.080 15Hx1W 2.30

Total Cutting Volume (cm3)

Carbide+Coating EPP4100 ø10

Comented Carbide

4teeth

Machine: Matsuura MC-800VF Side Surface Cutting, Dry, Downcut, Overhang: 35mm Tool Life Definition: Tool Wear 0.15mm

Cutting Speed Up 160 Cutting Verocity(m/min)

PLASTIC MOLD STEELS / CENA1

H.S.S.

2teeth

140 120 100

Doubled Tool Life

80 60

CENA1

40

P21 improved

20 0

0

500

1000

1500

2000

Total Cutting Volume (cm3)

6

Cutting Verocity Feed Cutting Depth Cutting Efficiency (mm/teeth) (mm) (cm3/min) (m/min) 80 0.080 15Hx1W 6.11 113 0.080 15Hx1W 8.64 150 0.080 15Hx1W 11.47

Machinability L/D=250

2.Endmilling Example

0.12mm

This sample was machined by one endmill for 22 hours. Machined surface roughness is very smooth.

Incline: 1.5° 30mm

Tool : ø 3.0 2 teeth

40mm

40mm

EPDR2030-30-05-TH (Hitachi Tool)

1.69mm

Machine : MAKINO V33 Cutting Verocity: 50m/min (5300min-1) Rz=2.3mm Ra75=0.26mm

Feed: 0.06mm/tooth (640mm/min) Cutting Depth: 0.06mm

PLASTIC MOLD STEELS / CENA1

Pick Feed: 0.12mm Dry (Air Blow) Cutting time: 22Hr Number of tool use: 1

3.Drilling Condition Deep hole machining condition Dia.

Cutting Hole depth Verocity Step feed Feed (mm) (mm) (mm/rev) (m/min)

Gread

Machined hole number

Step back

Remarks

ø0.6

SKH51(M2)

10(16D)

15

0.001

0.1

20

• Procedure

ø1

SKH51(M2)

10(10D)

20

0.003

0.2

60

ø1

Co-HSS+Coating

10(10D)

20

0.003

0.2

220

1.Positioning (Starting drill)

ø1

Cemented Carbide +Coating

10(10D)

25

0.003

0.2

820

ø2

SKH51(M2)

20(10D)

10

0.05

0.9

55

ø3

SKH51(M2)

30(10D)

12

0.05

1.2

60

ø4

SKH51(M2)

40(10D)

12

0.05

1.3

83

ø5

SKH51(M2)

50(10D)

12

0.06

1.5

105

ø7

SKH51(M2)

42(6D)

15

0.1

2

200

ø10

SKH51(M2)

90(9D)

13

0.13

2

50

130° 1.0

Machine : Vertical Machining Center

2.Machining drill

Solution : Emulsion

Deep hole machining condition example by Gun drill Dia.

Hole depth (mm)

Cutting verocity (m/min)

Feed (mm/rev)

Ejection pressure of cutting fluid (MPa)

Machined hole number

ø3

80

25

0.007

4.9

6

ø5

150

19

0.005

4.9

6

ø11.5

500

48

0.012

3.6

8

ø18

600

35

0.014

3.4

7

ø25

700 63 800

47

0.02

2.9

6

55

0.03

2.9

3

ø30

Machine : Vertical Gundrill

Solution : Oil

7

Remarks

Inner angle 20°

Quter angle 30°

Mirror Polishability

Crepability

CENA1 has very low non-metallic inclusion content and excellent mirror polishability.

CENA1 has homogenized micro structure and good crepability. CENA1 is suitable for precise creping.

60 Mirror Polishability Comparison

420 improved

Hardness(HRC)

50

CENA1

40

30

P20 improved #3000

#8000

#14000

·EDM surface Etching ··· Sand blasting treatment is needed before etching. ·Welded Surface Etching ··· Post-heating (≤ 200°C) after welding is needed before etching.

ED Machinability

Nitriding Property

CENA1 has good EDMachinability. As surface hardened layer is much less than conventional grades, CENA1 is able to be polished easier after EDMachining.

By nitriding, 1000HV surface hardness is obtained easily on CENA1, that is effective against wearing of slide core or mold for reinforced resin. Hardness Profile of Nitrided Cross-section 1200

Gas Nitriding 510°CX10h

1000 Hardness (HV)

PLASTIC MOLD STEELS / CENA1

Non-glare treatment Sample

Photo Etching Sample

Polishing Grain size No.

CENA1

800 600

P21 improved

400

EDMachined Sample

200

CENA1 100x100x50(mm)

0

0

0.05

0.1

0.15

0.2

0.25

Distance from surface (mm)

(Condition) Machine: HQSF(MAKINO), EDGE2S #108 Solution: Paraol 250 A d d i t i v e : μSC (0.8-1.0g/L) Electrode: Gr 78.0mm (EDM depth 1.0mm) Cu 79.2mm (EDM depth 0.4mm) Cu 79.7mm (EDM depth 0.15mm)

• The care is necessary to avoid breakage by overhardening especially for small dia. pin or sharp edge part. It is recommended to apply lower nitriding temperature or soft nitriding condition. 67

8

Weldability

• Welding Procedure Example

As welded area hardness variety of CENA1 is less than conventional grades, mold is able to be repaired and finished easily.

Welding Post-heating 200~400°C

EDM

Etching

Endnilling

145

Pdishing(#8000)

Pre-heating 200~450°C

ø2 drill

ø1drill

*

Tempering 520~550°C

Welded peat

10 R8

2

1h/25mm Air Cooling

>100°C

ø5 drill

ø5reamer

M6

20

20

*

Welding repair is recommended to be done by TIG welding with CENA1-W rod. 500 Hardness (HV)

PLASTIC MOLD STEELS / CENA1

Tempering

400 300

HAZ

HAZ Welded zone

200 -20

-15

-10 -5 0 5 10 Distance from Center (mm)

15

20

Photograph shows mirror polishing, creping, EDM and endmilling finished sample after welding repair (10mm width). No weld mark is obserbed on each finished surface.

Measured Surface Hardness of Welded Area

Hardness Distribution and Physical Properties Machanical Properties

• Hardness Distribution

CENA1 shows almost uniform hardness distribution even in large cross-section material.

40.2 40.2 40.3

40.0

• Specific Grabity 7.78 • Thermal Conductivity Grade

20°C

100°C

200°C

300°C

CENA1

28.1

28.3

28.8

30.1

P21 improved

32.2

32.2

33.0

34.3

• Thermal Expantion Coefficient

40.5 40.3

Average value from 20˚C, x10-6/˚C

40.4

Measured hardness of flat bar 200t X 510w cross section.

• Mechanical Properties

Machanical properties are almost same as P21 improved grade. Representative value of flat bar 50tX400W. Grade

Hardness (HRC)

W/(m·K)

Reduction 2U charpy Tensile Strength Elongation of Area impact value (%) (J/cm2) (%) (N/mm2)

CENA1

40

1,225

15

50

20

P21 improved

40

1,225

20

50

20

9

Grade

100°C

200°C

300°C

400°C

CENA1

11.0

11.4

12.0

12.5

P21 improved

11.3

11.6

12.4

12.8

• Young's Modulus 205GPa

1

Chemical compositions AISI JIS equivalent equivalent

C

Cr

W

Mo

V

Co

YXM1

SKH51

M2

0.80~0.90

3.80~4.50

6.00~7.00

4.80~5.80

1.80~2.30

_

YXM4

SKH55

M35

0.85~0.95

3.80~4.50

6.00~7.00

4.80~5.80

1.80~2.30

4.50~5.50



M1

0.75~0.85

3.50~4.50

1.30~1.80

8.00~9.00

0.90~1.30

_

SKH59

M42

1.00~1.10

3.50~4.25

1.25~2.00

9.00~10.00

1.00~1.50

7.75~8.75

Original Steel



1.00~1.10

3.80~4.50

5.00~6.00

6.00~7.00

1.50~1.80

7.50~8.50

SKH57



1.20~1.30

3.80~4.50

9.00~11.00

3.00~4.00

3.20~3.70 9.50~10.50

SKH2

T1

0.73~0.83

3.80~4.50

17.00~19.00



0.80~1.20

_

YXMT Molybdenum High Speed YXM42 Steel YXM60 Vanadium High Speed XVC5 Steel Tungsten High Speed YHX2 Steel YXR33 Matrix High Speed YXR3 Steel





Original Steel



Original Steel



HAP5R





HAP10





1.30~1.40

4.50~5.50

2.50~3.50

5.50~6.50

3.60~4.00

_

HAP40

SKH40



1.27~1.37

3.70~4.70

5.60~6.40

4.60~5.40

2.80~3.30

7.50~8.50

HAP50



1.54~1.64

3.70~4.70

7.50~8.50

5.50~6.50

3.80~4.30

7.50~8.50

2.02~2.32

3.70~4.70

9.00~10.00

8.00~8.50

4.80~5.10 9.00~10.00

YXR7

P/M High Speed Steels

HIGH SPEED TOOL STEELS

Conventional High Speed Steels

Grade

(mass%)

HAP72

Patented Steel



2

Applications and YSS grade Features Grade

YXM1 YXM4

Standard Molybdenum high speed steel with

Metal saw, Cutters, Cold punch, Dies

superior toughness

Hob, Drill, Reamer, Chaser, Cutters,

Standard Cobalt alloyed Molybdenum high speed

Heading tool for stainless, Endmill

steel with superior heat resistance

Tap, Roller dies

YXM34

Hob, Cutters

YXM60 XVC5 YHX2 YXR33 YXR3 YXR7 HAP5R HAP10

Features

Drill, Reamer, Broach, Chaser,

YXMT

YXM42

HIGH SPEED TOOL STEELS

Applications

Molybdenum high speed steel with superior grindability and toughness Cobalt alloyed Molybdenum high speed steel suitable for intermittent cutting

Drill, Cutters, Hob, Tap,

Super-hard high speed steel suitable for cutting for

Wood working tools

hard materials

Endmill, Hob, Broach, Cutters, Drill, Tap,

High-performance high speed steel with superior

Heading tool for stainless

durability, toughness and grindability

Tool bit, Cutters, Hob, Endmill,

High-performance Cobalt alloyed Vanadium high

Cold punch, Dies

speed steel with wear/heat resistance

Cutters, Broach

Standard Tungsten high speed steel

Warm forging dies, Hot forging dies,

Matrix high speed steel for forging tools with most

Cold forging dies, AI-die cast insert pin

superior toughness

Warm forging dies, Cold heading punch,

Matrix high speed steel for forging tools with

Trimming dies, Cold forging punch and die

superior toughness

Cold punch and die,

Matrix high speed steel for forging tools with

Fine blanking die, Thread roller die

superior strength/toughness

Severe forming tools, cold/warm forging

Toughest P/M high speed steel

dies, fine blanking dies Heavy duty working tools as fine blanking dies, Lower speed cutting tools as taps

HAP40

Cutters, Dies

HAP50

Heavy duty cutting tools for hard material

HAP72

Heavy duty cutting tools, Dies

Superior toughness effective to avoid chipping Most standard grade with good balance of hardness, toughness and wear resistance Higher hardness, good heat and wear resistance Good heat wear resistance and highest obtainable hardness of 70HRC

3

Recommended grade by application

•Cutting tools

( ) shows standard employed hardness/HRC.

Recomended Grade

Application Tool bit Drill

YXM1 (63~66)

Tap

YXM1 (63~66)

Reamer

YXM1 (63~66)

For high speed heavy duty cutting

For hard material cutting

YXM60, YXM42 (66~68) HAP50 (66~68), HAP72 (68~70) YXM20, YXM30 (65~67) HAP10, HAP40 (65~67) YXM4, YXM60 (65~67)

(65~67) HAP40, HAP50 (66~68) YXM30 (65~67) HAP45 (65~67) YXM4, XVC5 (65~67) HAP40, HAP50 (66~68) XVC5 (66~68) HAP50 (66~69), HAP72 (69~71) YXM30 (65~67) HAP10, HAP40 (66~68) HAP40, HAP50 (66~68) HAP10, HAP40 (64~66)

YXM4 (64~67)

Hob

YXM4, YXM1 (64~69)

YXM42, YXM60 (65~67) HAP40 (66~68) YXM60 (67~69) HAP72 (69~71) YXM60 (66~68) HAP10, HAP40 (66~68) YXM60 (67~69) HAP50 (67~69)

Pinion cutter

YXM1, YXM4 (63~65)

HAP40 (65~67)

Shaving cutter

YXM1 (64~66)

YXM30 (65~67) YXM42, YXM60 (66~68)

Rack cutter

YXM1 (63~66)

YXM4 (65~67)

YXM4 (65~67)

Chaser

YXM1 (62~65)

YXM30 (65~67) HAP10 (65~67)

YXM4, YXM30 (65~67)

Metal saw

YXM1 (63~66)

Hack saw

YXM1 (62~65)

Metal band saw

YXM1 (64~66)

Wood cutter

YXR3 (58~61) YXM1, YHX2 (62~65)

Milling cutter

YXM1 (63~66) YXM1, YXM4 (64~66) YXM60 (67~69) YXM1 (63~66) YXM4 (64~67)

End mill Broach

HIGH SPEED TOOL STEELS

For general use XVC5 (65~68) HAP72 (69~71)

•Cold working tools Application

Blanking die Cold heading die

Shearing blade (Straigh tooth)

Drawing dies Cold working rolls

Required hardness range HRC

HAP40 (66~68)

YXM42 (66~68)

YXM4 (65~67)

Recommended YSS steel For general use SLD, SLD8, ARK1

For mass production use For abrasion resistance

For impact resistance

XVC5, HAP40

YXM1, YXR7, HAP10

Male die

58~62

SLD, SLD8, ARK1

HAP40

YXM1, YXR7, YXR3

Female die

55~60

YSM

SLD, SLD8

YXM1, YXR7, YXR3

For sheet service

55~60

SLD, SLD8, ARK1

YXM1, YXR7

For medium plate

55~58

SLD, SLD8, ARK1

For heavy plate

48~53

DM, DAC

54~60

SLD, SLD8, ARK1

YXM1, HAP40

YXR7, YXR3

For sheet use

55~60

SLD, SLD8, ARK1

YXM1, HAP40

YXR7, YXR3

For heavy plate use

50~55

DM, DAC

58~62

SLD, CRD, ARK1

Bender Swaging dies Cold working dies

YXM42 (66~68) HAP40 (66~68) YXM42 (66~68) HAP40 (66~68)

58~62

Rotary shear slitter Trimming dies

YXM42, YXM60 (65~67) YXM4 (65~67) YXM42 (66~68) HAP40 (66~68)

YXR3 YXR33

XVC5

YXM1, YXR7

Male die

58~62

SLD, SLD8, ARK1

YXM1, HAP40

YXR7, YXR3, HAP10, HAP5R

Female die

55~63

SLD, SLD8, ARK1

YXM1, YXR7

YXR3, HAP5R

57~62

YXM1, CRD

XVC5

SLD

YXM1, HAP40

80HS

Thread rolling dies

58~64

SLD, SLD8

SLD10, YXM1, YXR7

Coining dies

57~62

SLD

YXM1, YXR7

Cold hobbing dies

55~60

SLD

YXM1, YXR7

Thead cutting dies

60~64

SGT, SAT

YXM1, YXR7

4

Heat Treatment Conditions Standard heat treatment conditions

•Annealing

1. All material is delivered as spheroidized annealed condition. 2. When used after reforging, spheroidized annealing is to be done before hardening. 3. Stress relief annealing is to be done in order to remove stress occured by cold working such as cold drawing, cold rolling or cutting and machining. • Heating temperature : 650~750˚C (to aim higher temperature when softening required) • Holding time:1h/25mm thickness

•Holding time of austenitizing

Preheat 1st 500-550˚C 30minutes/25mm thickness

When the object is of simple shape with thickness less than 50mm

2nd 850˚C

2 X figure of following table

or when facilities are restricted, 2nd and 3rd steps are combined to

3rd 1,050˚C

2 X figure of following table

one step with 850~900˚C X 2 X table-1. When the object is small,

HIGH SPEED TOOL STEELS

1st step may be skipped.

•Tools of ordinary shape Austenitizing temperature

Table 2nd stage preheating 850˚C 1st stage preheating 500~550˚C

Holding time quenching x 2

(Remarks) As for simple figure tools, 1st stage preheating can be skipped and oil quenching can be applied instead of hot salt bath quenching. For complex figure tools, 3rd stage preheat (1,050˚C) applying is preferable.

Gradual cooling Tempering

450~550˚C 30min/25mm

30min/25mm

About 80˚C

•Holding time at austenitizing temperature Heating furface

Time

Thickness (mm)

Holding time (sec)

5

10

20

30

40

50

60

70

80

90

60

90

160

240

280

350

390

420

440

495

X12

X9

X8

X8

X7

X7

X6.5

X6

X5.5

X5.5

Salt bath Magnification(Holding time/Thickness) (Remarks) Holding time in salt bath = dipping time

•Holding time at tempering temperature Thickness

≤ 2.5

26-35

36-64

65-84

85-124

125-174

175-249

250-349

350-499

Tempering holding time (hour)

1

1.5

2

3

4

5

6

7

8

(Remarks) Tempering is needed more than 2 times for grades contain no cobalt and needed more than 3 times for grades cobalt alloyed in order to make it tough enough.

5

Quenched and tempered hardness curve YXM1

YXMT

YXM4

70

70

68

68

68

1,220˚C

66

1,260˚C 1,240˚C

64

1,200˚C 1,180˚C

64

62

Hardness HRC

Hardness HRC

Hardness HRC

1,240˚C 1,220˚C

64

62

66

1,220˚C

66

1,200˚C 1,160˚C

1,200˚C 62 1,180˚C 60

60 60

58

58

56

500 520 540 560 580 600 620 Tempering temperature˚C

YXM1 Tempered hardness

56

500 520 540 560 580 600 620 Tempering temperature˚C

YXM42

500 520 540 560 580 600 Tempering temperature ˚C

YXMT Tempered hardness

YXM4 Tempered hardness

XVC5

YXM60

70

70 70

1,220˚C

69

68

1,260˚C

1,200˚C 68

67

1,180˚C

1,160˚C

66

66 1,160˚C

1,240˚C

66

1,180˚C Hardness HRC

1,200˚C

Hardness HRC

Hardness HRC

68

1,220˚C 1,200˚C

64

1,180˚C

62

1,160˚C 64

65

62

500 520 540 560 680 Tempering temperature˚C

YXM42 Tempered hardness

YHX2

56

64

60 1,125˚C 1,150˚C

1,180˚C

500 520 540 560 580 600 620 Tempering temperature˚C

YHX2 Tempered hardness

Hardness HRC

1,220˚C

58

1,175˚C

60

1,200˚C 58

62

62

64

1,240˚C

YXR33

66

1,160˚C

1,280˚C 1,260˚C

62

520 540 560 580 600 620 Tempering temperature˚C

XVC5 Tempered hardness

YXR3

1,300˚C

60

58

500 540 560 580 600 Tempering temperature˚C

YXM60 Tempered hardness

68

66

60

56 Hardness HRC

64

Hardness HRC

HIGH SPEED TOOL STEELS

58

1,180˚C

1,160˚C

58 56

54 52

54

50

52

48

50

46

48

500 550 600 700 Tempering temperature˚C

YXR3 Tempered Hardness

6

44

1,140˚C 1,120˚C 1,080˚C

500 550 600 650 Tempering temperature˚C

YXR33 Tempered hardness

Quenched and tempered hardness curve YXR7

HAP10

HAP5R

70

70

66

1,200˚C 1,180˚C 1,160˚C 1,140˚C

68 68

1,180˚C

64

1,140˚C 64

62

60 1,120˚C 1,100˚C

60

62 60 58

58 1,120˚C

1,120˚C

64

1,140˚C

62

Hardness HRC

1,160˚C Hardness HRC

Hardness HRC

66

66

1,160˚C

1,180˚C

1,100˚C

56

1,075˚C

56

1,050˚C 1,025˚C

54 54

500 520 540 560 580 600 Tempering temperature˚C

500 520 540 560 580

70

68

560

580

600

HAP72 72 1,160˚C

1,220˚C 1,200˚C

1,140˚C

540

HAP10 Tempered hardness

HAP50

1,200˚C 1,180˚C 1,160˚C

520

Tempering temperature˚C

HAP5R Tempered hardness

HAP40 70

52

600

Tempering temperature˚C

YXR7 Tempered hardness

70

68

1,180˚C

66

1,120˚C 1,100˚C 1,075˚C

60

56

520

540

64

66

1,220˚C 1,200˚C

64

62

1,050˚C 1,025˚C

58

1,160˚C

Hardness HRC

62

Hardness HRC

64

68

1,180˚C

66 Hardness HRC

HIGH SPEED TOOL STEELS

58

560 580

62 60 600

Tempering temperature˚C

HAP40 Tempered hardness

500 520 540 560 580 600 Tempering temperature˚C

HAP50 Tempered hardness

7

60

500 520 540 560 580 600 Tempering temperature˚C

HAP72 Tempered hardness

Properties Comparison of Properties (Based on YXM1 properties) Elevated temperature hardness

High

HA P7 2 C5

XV

HA

P1 0

P4

YX

Heat treated hardness

HIGH SPEED TOOL STEELS

HA

Wear resistance

M

High R3

YX

0

1

YX

High

M

60

HAP5 R

YXM1 YXM60 XVC5 YXR3 HAP10 HAP40 HAP72 HAP5R

Grindability

High

Toughness

8

High

Properties Bending strength

20

200 YSM

YXR33

ARK1

10

HAP5R

YXR3

100

6 SLD8 YXR7

4

HAP10

YXM1

56

58

60

62

66

68

70

XVC5

V4

100

0

56

58

60

62

64

66

68

70

72

1000

Hardness HRC

Grindability

Surface grinder : PA80K74 Wheel Wheel speed : 1,820m/min : 5µm/Pass Infeed Total infeed : 0.5mm Wet grinding

100

: DM (357HB) Work : Automatic lathe Machine Tool tip shape : 8-15-6-6-20-15-0.5R Cutting speed : 25m/min Depth of cut : 1mm : 0.3mm/rev Feed Dry cutting

150

Cutting condition

300 0

2000

cemented carbide

600

Grade

V5

50

900

3000

CRD

Index of grindability (SKH51=100)

Tool life (sec.)

HIGH SPEED TOOL STEELS

1,200

HAP72

SGT

300

20

Continuous Cutting test by turning tool

1,500

4000

YXM4

SLD

HRC Hardness

1,800

5000

HAP40 400

200

XVC5

64

HAP10

YXM1

V6

40 HAP40 HAP72

YXM4 54

YXR7

ARK1

6000

HAP5R

60

SLD

2 0

500

150

15

YXR3

600

YXM1 YXM4 YXMT YXM42 YXM60 XVC5 YHX2 HAP40 HAP50 HAP72

Wear resistance (Ogoshi method)

HAP10 HAP40 HAP50 HAP72 YXM1 XVC5

Wear resistance (Abrasive Wear)

Specific wear (mm3/(mm2·mm)x10-7)

Grade

Hardness (HRC)

YXM1

65.5

YXM4

65.0

XVC5

67.0

YXM1

65

YXR33

58.0

YXM4

65

YXR3

59.0

XVC5

67

YXR7

65.0

YXR3

61

HAP10

64.0

YXR33

58

HAP40

67.2

HAP10

65

HAP72

70.0

HAP72

70

SKD11

60.5

SKD11

59

SKD61

55.5

Co-friction material Friction length

0.5

1.0 Grade

1.85 Load Friction speed

9

Hardness (HRC)

Wear (Volume loss ; YXM1=1) 1.0 Rotate

2.0

3.0 Test picece(ø6) Slide Sandpaper

Test condition Sandpaper: Al2O3 #500 Revolution: 980rpm Friction length: 1000mm Lubricant dry Load: 49N (5kgf)

N/mm2

250

Bending Strength

25

J/cm2

10R Charpy Impact Value kgf·m/cm2

Charpy impact value

Hitachi Metals, Ltd. Head Office

http://www.hitachi-metals.co.jp/

SEAVANS North Building, 1-2-1, Shibaura, Minato-ku, Tokyo 105-8614, Japan Specialty Steel Company

Tel. +81-3-5765-4410 Fax. +81-3-5765-8317

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Tel. +65-6861-7711 Fax. +65-6861-1519

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•The characteristics listed in this catalog are representative average values which may differ from actual product characteristics.

•This catalog and its contents are subject to change without notice. •Do not duplicate this catalog without Metals,Ltd.

permission from Hitachi

•Please contact a representative of our Specialty Steel Division if there are any questions or problems.

Our address and contact indicated in this catalog are those as of November 2007. If you cannot put a call through, please contact our Corporate Communication Group. in Tokyo below. Tel:+81-3-5765-4076 Fax:+81-3-5765-8312 E-mail : [email protected]

January 2008 (PDF)