Selecting the Right Tool Steel for Your Metalforming Application.

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1 Selecting the Right Tool Steel for Your Metalforming Application. Patricia Miller, Senior Technical Manager What parameters drive your tooling material choice? Application Work materials Failure mechanism of tooling steel Production method of the tooling steel Serial length Complexity of geometry 1

2 What parameters drive your tooling material choice? Application Work materials Failure mechanism of tooling steel Production method of the tooling steel Serial length Complexity of geometry Cold Work Applications 2

3 Overview of Today s Working Materials Grades with good ductility Copper and copper derivatives Aluminum Mild steel Stainless steel Grades with less ductility Cold rolled steels Spring steels Hard materials Grades with higher abrasive nature Electrical steels Ceramics Hard metals Common Work Materials 3

4 Formability, A 80 (%) Work Material Comparisons: Cold Forming and Stamping IF Mild Steel HSLA Bake Hardenable Trip-steel DP-steel Mart. steel MPa KSI ~125HB ~180HB ~22HRC ~33HRC ~38HRC ~44HRC High Strength Stainless Steel Boron - steel Du Dual Phase Alloys Strength MPa 30% martensite 70% ferrite 50% martensite 50% ferrite 100% martensite 4

5 Third Generation Developments: Sheet Metal Grades Influence of Sheet Material Strength Sheet thickness: 1 mm (0.039 ) High force 1400 MPa M 800 MPa 500 MPa 280 MPa Punch diameter: Ø 4.80 mm (0.19 ) Die clearance: 10% Shock wave during breakthrough 5

6 Introduction to Tooling Failure Types Tool Steel Failure Mechanisms 6

7 Failure Mechanisms in Cold Work Wear (abrasive or adhesive) Results in a material loss and is related to the sheet material type, the application and the process conditions Abrasive Wear Adhesive Wear Abrasive Wear Material is lost because of friction between tooling and work material This is a predictable failure Solutions for Abrasive Wear Abrasive wear resistance is normally base on hardness and / or carbide volume of the tooling material Tooling material Surface Treatments 7

8 Wear Resistance is a function of Volume fraction and type of primary alloy carbide in the heat treated microstructure: Chromium carbide (M 7 C 3 ) HRC Molybdenum carbide (M 6 C) HRC Tungsten carbide (M 6 C) HRC Vanadium carbide (MC) HRC Distribution of primary carbides Size of primary carbides (severe abrasion only) Hardness, quality and type of heat treatment Adhesive Wear Normally referred to as micro-welding of tooling material to work material. Tooling material is pulled out. Is often misdiagnosed as abrasive wear. Solutions to Adhesive Wear: Tooling material, improving chipping resistance. Pull-out 8

9 Chipping Is related to the stresses in the process and the fatigue resistance of the tool material. Chipping D2 Uddeholm Vanadis 4 Extra SuperClean Plastic Deformation Occurs if the process stresses are higher than the compressive strength of the tool steel. 9

10 Cracking Occurs when the process stresses, and presence of an existing crack result in a stress level higher than the toughness of the tooling material. Galling Is a physical and/or chemical adhesion of the work material to the tool surface. The severity of galling depends on the surface finish and chemical composition of the tool steel and work material. Proper use of surface treatments can also reduce galling. 10

11 Method for Steel Selection in Cold Work Applications Identify the dominating failure mechanism. Select a tool steel with better resistance to the dominating failure mechanism. Goal: Reliable and economical production: The choice will depend on the steel s inherent capabilities and its production method. Today s Tool Steel Options 11

12 Conventional / Ingot Steel Production Melting Shop EAF Ladle Furnace Vacuum-De-Gassing Uphill Casting ESR Re-Melting Stock Machining Heat Treatment Forging Plant Rolling Mill Customer Inspection & Testing Tool Steel Production: Hot Working High Reduction Forging Breakdown of the solidification structure to obtain a fine-grained austenite and freedom from carbide networks. 12

13 D2 Structures: Can be very different from each manufacturer Tool Failure: D2 Punch made from standard D2 premature failure Starting material: bar rd. 33 mm 13

14 Carbide Distribution Controlled Carbide distribution with Bohler K110 Standard Grade Bar rd. 33 mm, Direction: Longitudinal / Magnification: x 100 The cold work tooling environment: Conventional Grades The most popular tool steels for blanking; trim, forming and calibration dies: AISI A2: 5 % Chromium steel, air hardening, general purpose, hardness is HRC. AISI D2: 12 % Chromium steel, air hardening, high wear resistance, hardness of HRC. These grades are not always suitable for demanding coldwork applications. Not easy to salvage when chipping, wear, or galling take place. 14

15 The Goal: Extend the life of the tool first by minimizing failure modes like chipping so that we can address the wear failure modes. Tool material with carbide stringers Time for crack initiation Time for crack propagation Tool lifetime Tool with poor surface finish Tool with EDM-surface layer Conventional Tool Steel Production with Secondary Melting Electroslag remelting The small amount of liquid metal solidifies much faster than a large steel melt which gives: Less time for carbide growth during solidification. improved homogeneity and smaller carbides. The remelting takes place under a liquid active slag layer which removes inclusions. Consumable Molten Slag ESR ed Ingot Water Cooled Mold Remelting under protected atmosphere 15

16 Benefits of Re-Melted Steel More consistent structure in the steel More consistent to machine. Easier and more consistent to heat treat. Much higher toughness and more uniform in all directions. Permits new grade development Allows for high temperature tempered grades to replace older versions. Better stability in operation. Easier to coat. Greater versatility in the types of coatings to use. More uniform wear rates, with less chipping. Quick overview of BU Tooling Materials for High Strength Work Materials Conventional Produced and Remelted Bohler W360 Isobloc : An ESR produced very high toughness hot work tool steel, high temperature tempered to HRC. Uddeholm Caldie : An ESR produced high toughness medium wear resistance tool steel. With a typical working hardness of 58-62HRC and high temperature tempering. Readily weldable and coatable. Bohler K340 Ecostar /Isodur : A medium toughness good wear resistance tool steel. With a typical working hardness of 58-64HRC and high temperature tempering. Use instead of M2, M4, D2. 16

17 Results from Production Tools 8 Trim dies in Caldie PVD TiCN coated DP 600 sheet; 1.8 mm (0.071 ) thick Production since 2005: 800,000 parts/die with no downtime. In total, over 2.5 millions parts have been produced. Microstructure Comparison AISI D2 8% Cr Steel ESR Photo Micrographs are at 500x 17

18 Powder Metallurgical (PM) Steel Production PM PRODUCTION ROUTE 8 T heat size Large Tundish with ESH and EMS Fine powder gas atomization Direct capsule filling without extra powder handling Cold Load Hot Unload HIP Powder Metallurgical Steel Advantages Advantages to Tool Users Wider selection of grades that can have better wear characteristics. Less variation in performance. Reduced risk of cracking and chipping failures. Reduced risk of fatigue failures. Longer tool life Less Downtime and Maintenance = Improved Profitability 18

19 Powder Metallurgical Steel Advantages Advantages to Tool Makers More uniform response during tool making with regards to: More consistent machinability/grindability. Reduced risk of problems during EDM. Reduced risk of problems during polishing. Improved adherence of surface coatings. Powder Metallurgical Production Process Improvements in Cleanliness PM 4V Conventional Steel (AISI D2) Standard Market PM Bohler-Uddeholm PM 19

20 New PM Technology: PM + Nitrogenated Powders Dense distribution of very low friction* nitro-carbides (M(N,C) to support the work material. Many deep lubricant reservoirs. Surface polished to Ra µm * Much lower friction coefficient than the carbides in our other PM steels. Quick Overview of Tooling Materials Powder Metallurgy with Uddeholm SuperClean Technology Uddeholm Vanadis 4 Extra SuperClean: High toughness with good wear resistance PM tool steel. Typically hardness range of 58-64HRC with high temperature tempering. Uddeholm Vanadis 8 SuperClean: New Development for Trials PM steel, used in applications where abrasive wear resistance is critical. Typical hardness range is HRC. Uddeholm Vancron 40 SuperClean: Medium toughness with excellent resistance to galling. Typical hardness range 58-65HRC, with heat treatment similar to Vanadis

21 Uddeholm Vanadis 4 Extra SuperClean Case Study: Vancron 40 SuperClean Galling / flaking of TD coating on D2 Vancron 40 coated with PVD Coating by Thermo Tech produced 500,000 parts and still running customer commented that the insert still looks GREAT! Forming Die for Producing a Bolt Fastener Part Produced part Bolt fastner part for Mid Sized trucks. Sheet Steel Uncoated HSLA Steel, Hytens 55 ksi, Rm=350 MPa, HRPO t=5 mm Tool Steel and Production Conditions Uncoated Vancron 40 and D2 TD Coated Dimension: 3.50 x 4.00 x 5.00 Hardness: 60 HRC Surface Roughness: Ra=0,1 um? Lubrication: 10% Oil Emulsion Press speed: 60 parts/min 21

22 Case Study: Vancron 40 SuperClean Quick overview of Tooling Materials Powder Metallurgy with Bohler MICROCLEAN Technology K890 MICROCLEAN : Extremely high toughness in a PM tool steel: 3 Percent Vanadium Grade. S693 MICROCLEAN : Good combination of wear resistance and ductility in a PM steel: high carbon PM M4. K294 MICROCLEAN : Very high wear resistance in PM steel: a third generation PM A11. S390 MICROCLEAN : Modified PM T15 with extremely high hardness capabilities and compressive strength. 22

23 Putting it all Together Critical questions..just as with your work materials Does your tool steel source produce the grades they supply to you? Do you know how the steel is being produced? Do they address your concerns and provide corrective action when you need it? Do they create new grades to address your current and future concerns? Supplier s contribution: Premium Grade Tool Steel Application-Designed Steel Full Technical Service 23

24 General Comparison: Abrasive Wear Resistance vs. Toughness UDDEHOLM VANADIS 8 SUPERCLEAN 47 Tool Steels for Good Chipping Resistance Bohler W360 Isobloc Uddeholm Caldie Bohler K340 Ecostar /Isodur Uddeholm Vanadis 4 Extra Chipping Resistance Hardness 24

25 Tool Steels Used for Wear Resistance Abrasive Wear Uddeholm Vanadis 8 SuperClean Bohler K294 MICROCLEAN Adhesive Wear Uddeholm Vanadis 4 Extra SuperClean or Uddeholm Caldie Combination Bohler K340 Ecostar /Isodur Uddeholm Vancron 40 SuperClean Tool Steels Used for Galling Resistance Uddeholm Vanadis 4 Extra SuperClean Uddeholm Vanadis 8 SuperClean Uddeholm Vancron 40 SuperClean Add coatings when needed! Improved Galling Resistance 25

26 Tool Steels for High Compressive Strength Uddeholm Vanadis 4 Extra SuperClean Bohler S693 MICROCLEAN Bohler S390 MICROCLEAN Total Tooling Economy: Bring all of your costs to the surface 26

27 Please join us for our next webinar in early 2016 Upgrading Your Tooling Performance with Application Specific Heat Treatment and Coatings. Questions? 27

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