tool steels simplified

Tool Steel – Simplified

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Purpose

Purpose of this presentation:

– Give you greater confidence that Mate’s punch and die materials are the best in the industry

– Give you greater confidence that you can sell these advantages

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D2 A18 M2 PD-5 Ultima M4

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Wear Resistance

Toughness

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Tool Steel Advantages

Which qualities are the Customers looking for ?

– Quality Product• Performing, dependable, reliable, consistent

– Wear Resistance (Adhesive vs. Abrasive)• Resistance to wear from gummy materials – stainless• Resistance to wear from abrasive materials – hot rolled• Provided by hardness level and chemistry (carbide composition)

– Toughness and Good Fatigue Life• Resistance to breakage (fracture) and chipping; impact strength• Opposite of brittleness• Is not same as Hardness

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Which qualities are the Customers looking for ?

– Hardness • Resistance to deformation (compression, indentation)• From 58 to 64 HRc, typical 60-62 HRc

– Price• Must fit the value proposition for the appropriate market

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– Red Hardness (= Heat Resistance = Anneal Resistance)• Ability to sharpen the product without damaging the material as well as

being able to coat it (heated operations)

Tool Steel Simplified

Basic Structure

Matrix (Base):

• The mortar that holds the road together

• Matrix compositions can be altered to enhance toughness, hardness, heat resistance, corrosion resistance

Carbides:

•Offer resistance to abrasion similar to cobble stones

•Carbide volume and composition can be altered to offer enhanced wear resistance usually at the expense of toughness and fabricability/machinability

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• Carbides consists of Carbon (0.5 to +2%) in combination with alloying elements

• Cr (Chromium)• Mo (Molybdenum)• Si (Silicium)• W (Tungsten)• V (Vanadium)

• The carbides are harder than the matrix and provide the wear resistance

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• The carbides are formed during the fabrication process and can be from 5 to 20% of the tool steel (“alloy content” or “carbide content”)

• Amount and type of carbides are different in different tool steel grades A2 – D2 – M2

• More (hard) carbides give more Wear Resistance, but less Toughness (more brittle) – “trade off”

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Correct chemistry is important

•A minimum amount of Carbon is needed to • form carbides during the manufacturing process, and • harden sufficiently during the heat treatment process

•The total carbide content (in quality and quantity) is important for the Wear Resistance,

Vanadium (V) carbides are the hardest and contribute most M2 steel contains 2% Vanadium M4 steel contains 4% Vanadium

•Vanadium: forms very wear resistant carbides, but it also can imbrittle the material. Eexpensive.

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Correct chemistry is important

•Chromium (Cr): causes more uniform hardness while forming carbides and increasing the strength of the material matrix. Is least effective for the Wear Resistance. Also leads to size instability in sufficient quantity (D2).

•Silicon (Si): helps to increase toughness and strength when used with other alloys.

•Tungsten (W): dramatic impact on hardness and resistance to heat effects in higher quantity (HSS materials). Expensive.

•Molybdenum (Mo): helps to increase hardenability and red-hardness when present with other alloys like chrome and manganese. Also forms good wearing carbides.

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The higher the Wear Resistance …

… the lower the Toughness.

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- At a similar hardness, greater amount of carbides will show better wear resistance

- The higher the hardness for the same carbide, the lower the toughness


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Notes:-The total Carbide volume determines the wear resistance (abrasive and adhesive).-“High Speed Steel” starts at 3-4% Tungsten, Molybdenum is important too-Wilson’s proprietary A18 is A18 plus a little Tungsten, not enough for HSS

Conventional Tool Steels

HSSHSS

Results and Comparisons

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Note: -M4 is not M4PM!-Amada still uses a lot of D2 (e.g. in slitting blades)-DuraSteel has more Toughness and Abrasive Wear Resistance than M2, less Adhesive Wear Resistance-in general, dies need more toughness (cantiliver effect), punches more wear resistance

P20 17-4

17-4 H11,H13

S2, S5

S7

W1

L2 420, L6

H14, H21

H19 3V 9V

H24 3V 9V

L2 L3 A2, H26

M4

O1 T1, M2

T2

T4 D2, M3

M4, T15

10V

T5 D4 A7, T15

Histar40

A18Cruwear

Vertex

Conventional Tool Steels

Abrasive Wear Resistance


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Note: -Wear Resistance = Abrasive + Adhesive

How is a Tool Steel made ?

Manufacturing Process (conventional way)

1. Desired chemical composition is melted in large batches




2. Poured into “ingot molds” to solidify

• Carbides are now formed

• Slow solidification process will cause Carbides to form ‘interconnected’ segregation networks

• More carbides give more Wear Resistance and less Toughness, but high volumes of carbides (“high alloy steels”) result in more segregation (= non-uniform microstructure)

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2. Poured into “ingot molds” to solidify

• Carbides are now formed

• Slow solidification process will cause Carbides to form ‘interconnected’ segregation networks

• More carbides give more Wear Resistance and less Toughness, but high volumes of carbides (“high alloy steels”) result in more segregation (= non-uniform microstructure)

3. Rolled or forged into bars

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Manufacturing Process (conventional) (Contd.)

2 fundamental segregation problems:

o More carbides give more WR, but high volumes of carbides (high alloy steels) in a non-uniform structure due to segregation makes the tool difficult to manufacture (grinding problems; chipping)

o The segregations get elongated during rolling or forging, get directionally oriented and reduce toughness; grinding problems; chipping risk

For better tool steels, more carbide content is needed (especially higher Vanadium contents), but this imbrittles the tool steel (less toughness)

=> Different process needed ! 17


Non-uniform Carbide size and distribution

(> 50 microns)

Crucible Powder Metallurgy (CPM)

Especially designed for high Vanadium content alloys

1. Desired chemical composition is melted

2. Rapid solidification into fine droplets (“powder”)• 2-4 microns; segregation is virtually eliminated

3. Powder is consolidated• Powder particles are bounded together under high

pressure

4. Forged or rolled into bars

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How Is How Is Particle Metallurgy Particle Metallurgy Different From Traditional Different From Traditional Ingot Metallurgy?Ingot Metallurgy?

Induction Melting /Gas Atomizing

AOD Melting

Hot IsostaticPressing (HIP)

Ingot Casting

Rapidly SolidifiedSpherical Powder

Alloy Segregationat Billet Conventional M4

Microstructure

CPM M4Microstructure

Ingot Metallurgy

CPM Processing

(as-HIP or forged) 19


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CPM vs. Conventional

Powder Metalurgy allows higher volumes of Carbides, without segregation problems, even increasing Toughness

Results and Comparisons

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Abrasive Wear Resistance

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P20 17-4

17-4 H11,H13

S2, S5

S7

W1

L2 420, L6

H14, H21

H19 3V 9V

H24 3V 9V

L2 L3 A2, H26

M4

O1 T1, M2

T2

T4 D2, M3

M4, T15

10V

T5 D4 A7, T15

Histar40

A18Cruwear

MPM82

M4PM

$$$

Vertex

Vertex- Powder

PD-5

Note: -DuraSteel has more Toughness and Abrasive Wear Resistance than M2, less Adhesive Wear Resistance-Amada still uses a lot of D2-MPM82 is powder Cruwear (Durasteel)-Dies need more toughness (cantiliver), punches more wear resistance

Powder Metals shift the line!

Powder Metals shift the line!


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Notes:-The total Carbide volume determines the Wear Resistance (abrasive and adhesive).-“High Speed Steel” starts at 3-4% Tungsten, Molybdenum is important too- ‘M2’ and ‘M4’ mean high Molybdenum content and 2% or 4% Vanadium-Wilson’s proprietary A18 is A18 plus a little Tungsten, this not really HSS


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Note: -Wear Resistance = Abrasive + Adhesive-PD-5 is a grade of Wilson’s Ultima-Vertex (Powder) is used by Pass


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Benefits of Power Metallurgy:

Comparison of Wear Development on Conventional (left) and P/M (right) Tool Steel


Summary of Qualities Customers Look For:

– Quality Product– Wear Resistance (Adhesive vs. Abrasive)– Toughness and Good Fatigue Life– Hardness– Red Hardness– Price

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What does Mate Do?

– Mate optimizes toughness and wear for the appropriate application and market price

– Not all punching environments are the same

• Dies generally favor toughness (inherent to the shearing of the material more closely matching the punch size)

• Punches and dies in a less challenging environment favor wear (Trumpf and Thick Turret)

• Punches and dies in a more challenging application favor toughness (Typically Thin Turret and 112/114)

• Price sensitive markets prefer more economical materials (Thin Turret and 112/114)

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What does Mate Do?

– Mate controls the quality better than other tooling suppliers

• Mate has rigorous standards for each tool steel supplier

• We don’t shop for the cheapest material – Lower grade tool steels become a commodity at low price

• We know the best mills

• Mate accepts steel only from certified sources

• Tested on manufacturability, segregation, inclusions

• Mate uses world class heat treaters and heat treatment processes

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How Does Mate Achieve These Qualities:

• Control the Supply Chain– Audit materials against industry standards for a specific material

– Test the machining of the material for any change in machinability

– Independently section and test materials with an independent laboratory

• Control the Chemistry of the Material– Amount and Quality of Carbide Formation (Wear/toughness)

– Hardness (Wear/toughness/strength)

– Resistance to Heat (Red hardness)

– Size Stability

– Price (some elements cost much more than others)

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How To Achieve These Qualities

• Control How the Material is Created

– Controlling ingot sizes and yield %• Smaller sizes usually have less contamination and piping• Lower yield % means leaving the slag behind

– Controlling alloy distribution• Working (hitting/rolling/reducing) the material into smaller

billets• Re-melting the material• Particle Metallurgy

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Tool steel bars

Machining processes

Soft Blanks

Hardening

Hard blanks

Machining processes

Stock

Point Finishing

if required: Maxima Coating or Nitriding

Finished tool

• Control How the Material is Heat Treated

Heat Treatment

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• Control How the Material is Heat Treated (Creation of the Microstructure)

–Controls Properties of Hardness, Size Stability, and Carbide Formation for Wear Resistance

–Is Described by this Process:

• Preheating + Heating to the Austenitizing T° and holding it for a set duration- Creates uniform micro structure ”AUSTENITE””AUSTENITE”

• Quickly reducing the temperature (Quench Rate)- Makes it strong, but brittle and unstable ”UNTEMPERED MARTENSITE””UNTEMPERED MARTENSITE”

• Raising the temperature (Tempering Temperature) and repeating as necessary (Number of Tempers)

- A little less strong, but much tougher now ”TEMPERED MARTENSITE””TEMPERED MARTENSITE”

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Heat Treatment Process – low alloy steels

(Degrees Fahrenheit)

(Air or Oil)

(Hardened blank willneed grinding to size)

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Heat Treatment Process – high alloy steels


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Heat Treatment Process – high alloy steels


(Maxima not possible on Maxima not possible on low alloy steels)low alloy steels)

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Summary:

– Quality, Chemistry, Processing, and Heat Treatment are All Important!

– Trade off between Wear and Toughness

– Powder metals can help this trade off but adds costs

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Tool Steels Landscape

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M4PM lasts longer !!!

Trumpf style M4PM Punches vs Competitors

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M4PM lasts longer !!!Notes:

-Trumpf uses HSS (similar to M2) in Europe

-Wilson std. is A18; 2-4-1 is PD-5

-Pass uses Vertex (DC53) Powder

Thick Turret M4PM Punches vs Competitors

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Notes:

-Wilson std. is A18; EXP is PD-5

-Pass uses Vertex (DC53) (non powder)

-Amada still uses some D2

MPM4 lasts longest !!!!


Summary:

– Mate offers the best quality

– Mate offers the best characteristics for the application and market conditions

– Mate monitors changing market conditions (Competitive Analysis Program)

– Mate researches better materials and alternate tooling approaches (bimetal, insert products, etc.)

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Benefits of Powder Metallurgy Tools for End Users

• Very high consistency• Optimum tooling reliability• Cost recoverable through improved performance

– Increased wear resistance

– Increased toughness

• Improved machine up-time– Less frequent sharpening

– Less fall-outs due to breakage

“The Power of Powder”


Group exercise:

- Where do we use M4PM tool steel ?

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Size 0A/0B : M4Size 1 – std & QL : M2 M4 upgradeSize 2 – std & QLNEXT – complete lineMultitool 5 and 10 punches LongLife punch and die blades

Slitting blades Ultra A and B (optional)

See presentation

Trumpf:

Thick Turret:

Salvagnini:

Tool Steel – Simplified

Thank you !

tool steels simplified

Documents

hardness resistance

hardness level

red hardness

heat resistance

purpose purpose

greater confidence

wear performance

carbide volume2