Increasing the Efficiency of Metalform Tooling for Advanced High Strength Steels

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1 Increasing the Efficiency of Metalform Tooling for Advanced High Strength Steels By: Brett Krause and Tom Bell of Bohler Uddeholm Corporation

2 Introduction Information on Bohler Uddeholm Newly developed tool steel and processing What makes it different Properties of the tool steel Compared to current tool steel Current cold roll tooling case studies Tool Steels for Blanking and Forming of AHSS What works best and why

3 Bohler Uddeholm World largest producer of Tool Steel Austria, Sweden, Brazil Distribution in 37 countries In North America 15 service locations 400 employees Downstream processing Value added: cutting, grinding, and machining

4 Introduction Trends New steel making processes Trim and Draw die tooling Rolls for cold rolling of strip steel Suggested improvements for making steel more efficiently

5 What s new New process for producing tool steel Conventionally produced with addition of ESR Spray form New alloys that offer superior performance to commonly used tool steels

6 Background and History of Dan Spray Process Process similar to Spray Forming or Thermal Spray techniques for hard surface coatings Positioned between conventional ingot metallurgy and P/M process metallurgy Developed in the mid 1970 s by researchers who formed Osprey Metals Company Many different types of alloys can be produced by this process such as Al and Si alloys, copper alloys and iron alloys

7 What is the Dan Spray Process? A metal stream is atomized The atomized droplets are collected by a substrate which allows a pre-form to be made in the form of tube and billets Eliminates HIP ing The pre-forms are ready for further processing such as rolling or forging Exhaust Tundish Melting furnace Spray formed billet Spray chamber Collector disc

8 Microstructure Comparison Conventional 25µm P/M 3.5µm Spray Form 10µm

9 Spray Form Material for Roll Tooling Composition (wt%) Grades C Si Mn Cr Mo V W LCV Spray Form M M % Cr D

10 Spray Form - Property Comparison Conventional Metallurgy Grades Increasing chipping resistance S7 O1 A2 M1 M2 8% Cr D2 LCV Spray Form Spray formed Metallurgy Grades Increasing Wear Resistance

11 Case study LCV Spray Form Cold rolling Sendzimir Z- High Mill

12 Case study LCV Spray Form Cold rolling - work roll at four high mill COMPANY: PRODUCT: ROLLING MILL: ROLL DIMENSION: COMMENT: Sandvik Materials Technology, Sweden. Cold rolled high carbon, high chromium steel. Four high cold roll mill - three in line, Initial cold rolling of hot rolled strip to t = mm Work roll, Ø271x1555 mm. The surface at the roll bearing position is significantly better for LCV Spray Form. Phase 2 is to reduce regrinding depth to 0,10 mm for LCV Spray Form. Grinding with CBN is to be preferred. Phase 3 is to replace ROP 20 with LCV Spray Form in all three roll positions. Phase 4 is to improve performance further by increasing hardness of LCV Spray Form -. from 59 to 61 HRC - 63 HRC RESULT: ROP 20 (H13 MOD.) (0.7%C, 5.3%Cr, 1.1%Mo, 0.5%V) LCV Spray Form Phase 1 st Work Roll LCV Spray Form 2 nd Work Roll ROP 20 3 rd Work Roll ROP 20 Production Tonnage / Regrind 8 coils 28 coils Failure Mechanism Abrasive Wear Abrasive Wear Regrind Depth 0.3mm 0.3mm Hardness HRC HRC

13 Case study LCV Spray Form Cold rolling - work roll at four high mill COMPANY: PRODUCT: ROLLING MILL: ROLL DIMENSION: COMMENT: RESULT: Sandvik Materials Technology, Sweden. Cold rolled high carbon, high chromium steel. Four high cold roll mill. Intermediate mill, T = mm. Work roll, Ø 160 x 1245/510 mm. The surface at the roll bearing position is significantly better for LCV Spray Form. ROP 20 (H13 mod.) (0.7%C, 5.3%Cr, 1.1%Mo, 0.5%V) 8%Cr steel LCV Spray Form Produced tonnage/regrind 5 coils 7-8 coils coils Failure mechanism Abrasive wear Abrasive wear Abrasive wear Regrinding depth 0.15 mm 0.15 mm 0.05 mm Hardness HRC HRC HRC

14 Case study LCV Spray Form Calibration roll for manufacturing of welded stainless tube COMPANY: AST, Sweden. PRODUCT: Stainless tube, Ø38 mm. WORK MATERIAL: TOOL DIMENSION: 18/8 steel. Calibration roll direct after annealing, which is the most severe roll position from wear point of view, Ø 150 x 70 mm. RESULT: LCV Spray Form Hardness 62 HRC 60 HRC Produced hours/regrind 310 h 100 h Failure mechanism Minor abrasive wear D2 Abrasive wear, galling

15 Case study LCV Spray Form Circular slitting knife COMPANY: PRODUCT: WORK MATERIAL: TOOL DIMENSION: RESULT: Sandvik Steel AB, Sweden. Valve band (for shock absorbers). High carbon steel (20C), t = 0.6 mm, 1200 MPa. Circular slitting knife, Ø210 x 7mm. Sandvik has contacted their suppliers and asked them to make circular slitting knives in LCV Spray Form M2 LCV Spray Form Produced coils / regrind coils coils Failure mechanism Abrasive wear Abrasive wear Hardness 62 HRC 62 HRC

16

17 Work Material Testing Performed 70 High Strength Stainless Steels 60 Formability, A 80 (%) IF Mild Steel Bake Hardenable HSLA Trip-steel DP-steel Grades of AHSS Tested Mart. steel MPa KSI ~125HB ~180HB ~22HRC ~33HRC ~38HRC ~44HRC

18 UHS Work Material 1400 Mpa Flat punch Flat punch with a PVD coating Force,N Chamfered punch ,005 0,01 0,015 0,02 0,025 0, This shock wave can be avoided by a chamfer Time,s Punch Material P/M 4%V at 60 HRC ~30 % force reduction by chamfered punch

19 UHS Work Material 1400 Mpa Die Clearance Tool wear after strokes Tool steel: P/M 4%V at 60 HRC Punch wear (µm 2 ) µm µm µm Die clearance, % of strip thickness

20 UHS Work Material 1400 Mpa Surface Coatings Results after strokes Tool material Hardness Coating Die clearance P/M 4%V 60 HRC TiN 6%, 10% P/M 4%V 60 HRC TiC (CVD) 6%, 10% P/M 4%V 60 HRC TiCN 10% P/M 4%V 60 HRC TiAlN 10% All four examples showed spalled surface coatings

21 UHS Work Material 1400 Mpa Wear Mechanism 6% die clearance ( S7) - 58 HRC (D2) - 58 HRC P/M 4%V - 58 HRC Punch wear (µm 2 ) Number of blanks made

22 UHS Work Material 1400 Mpa Wear Mechanism after Strokes AISI S7 AISI D2 P/M 4%V Constant abrasive wear

23 AHS Work Material 1200 Mpa; Production Environment test of Blanking Punch Example 3 Tool Steels 8% Cr Tool Steel D2 P/M 4% V P/M 4% V Improved Appearance after strokes

24 UHS Work Material 800 Mpa Surface Coating Comparison after strokes Galling problems with uncoated tool Uncoated punch No galling with coating PVD coated with TiAlN

25

26 Other feedback with using alternative tooling materials with AHSS Caldie Bar Stock: New die steel an alternative: Easily Weldable Flame and Thru-Hardenable Inserted into cast steel / iron base Can be used for forming, blanking and trimming of Advanced High Strength (AHS) work materials. Carmo Granshots: Castable Tool Steel Has the ability to be through hardened Smaller cross sections Easily Weldable Easily flame-hardenable Trim and Draw dies

27 Conclusion For Cold Rolling Roltec offers superior wear resistance and surface finish for cold forming rolls. Vanadis 4 Extra and Caldie give an excellent combination of chipping resistance, compressive strength and wear resistance for blanking and forming of AHSS

28 Great Tooling Starts Here! Thanks for your attention Any Questions? METAL-20

29 Great Designs in Steel is Sponsored by: AK Steel Corporation Dofasco Inc. Mittal Steel Company Nucor Corporation Severstal North America Inc. United States Steel Corporation

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