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
8ø
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/
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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 :
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January 2008 (PDF)