02 03 MATERIALS ENGINEERING TOOLING ALLOYS

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1 en TOOLING ALLOYS

2 02 03 MATERIALS ENGINEERING TOOLING ALLOYS

3 CONTENT 05 EXCLUSIVE PRACTICAL EXPERIENCE 06 ASP STEELS 08 CPM STEELS 10 SIGNIFICANT ADVANTAGES OF POWDER METALLURGICAL HIGH PERFORMANCE STEELS 12 TOOL STEELS 14 SERVICES AND SPECIAL DESIGNS 15 LOGISTICS AND QUALITY 16 ADDRESS DIRECTORY

4 Zapp was founded in 1701 in Ründeroth, Germany by Hermann Zapp. Over the past 300+ years, Zapp has evolved into a global leader in premium, technologically advanced specialty materials. Today, the Zapp Group is a worldwide supplier with production facilities and service centers on three continents. Our core competencies lie in the manufacture and distribution of ready-to-use high performance materials for demanding applications. The Zapp Group s global operations consist of three divisions: Precision Strip, Precision Wire, and Materials Engineering for tooling alloys and specialty materials. Our objective is to offer technologically advanced solutions for the most demanding applications through close cooperation with our customers MATERIALS ENGINEERING TOOLING ALLOYS

5 EXCLUSIVE PRACTICAL EXPERIENCE WITH TOOL STEEL, SPECIAL ALLOYS AND POWDER METALLURGICAL STEELS 35 YEARS OF PRACTICAL EXPERIENCE With Erasteel and Crucible we represent two of most renowned manufacturers of powder metallurgical steels. We not only advise you on material selection, we also support you through the entire tool making process including determination of the appropriate heat treatment for your application. POWDER METALLURGICAL (PM) MATERIALS THE OPTIMUM FOR YOUR APPLICATION PM materials help you to extend service life and improve overall production efficiency. For this purpose, a large range of materials is available, from highly ductility matrix steels such as ASP 2012 to extremely wear resistant tool steels such as CPM 10V or CPM 15V. PRACTICE BRINGS PRODUCTS TO PERFECTION Our practical experience not only helps our customers, but also our suppliers to optimize their products for special applications. FOR A NEW GENERATION OF TECHNOLOGY Increasing demands from the automotive, food processing and plastics industries lead to growing demands on the materials used. High corrosion resistance, good wear resistance, and toughness, in conjunction with optimal processing characteristics, leads to the best service life in your process. See us as a reliable, competent partner who helps you to find the right answers to your questions.

6 ASP STEELS ASP STEELS In the production of ASP steels, liquid steel melt is atomized using nitrogen. The fine powder is encapsulated in a steel cylinder, evacuated, and then hot isostatically pressed. To avoid possible unwanted residual porosity, the material is subsequently compacted through hot forging and rolling. The patented Erasteel Dvalin TM process permits the achievement of high cleanliness in the steel production. For your applications, that means particularly high fatigue strength and the attainment of very fine surface finish. THE ASP MANUFACTURING PROCESS Graphite electrodes for heating of the melt bath and to maintenance of constant temperature 2. Slag blanket 3. Molten steel 4. N 2 gas 5. Atomization of the molten steel using nitrogen 6. Welding of the cylinders after evacuation 7. Isostatic hot compacting 8. Encapsulation ASP and TM DVALIN are registered trademarks of Erasteel, France (Paris) MATERIALS ENGINEERING TOOLING ALLOYS

7 ANALYSES AND PROPERTIES Typical analysis (standard values in mass-%) Steel designation ASP 2012 ASP 2017 ASP 2005 ASP 2023 ASP 2030 ASP 2053 ASP 2060 C Cr Mo W V Co Nb 1.0 MECHANICAL PROPERTIES OF ASP MATERIALS /D2 62 HRc /M2 62 HRc ASP HRc ASP HRc ASP HRc ASP HRc ASP HRc Wear resistance Toughness Data sheets and stock lists for the individual materials can be found at

8 CPM STEELS CPM STEELS Crucible is specialized in the production of high alloy powder metallurgical cold working and high speed steels. These high vanadium steels meet most demanding requirements for wear resistance and compressive strength. For special applications requiring high corrosion resistance, CPM 420V and CPM S30V are successfully employed in practice. All CPM steels are also hot formed in order to achieve optimum properties. THE CPM MANUFACTURING PROCESS Atomization 2. Powder 3. Filtering 4. Filling 5. Encapsulation 6. Hot isostatic pressing 7. Forging 8. Rolling CPM is a registered trademark of Crucible Industries LLC, U.S.A. (Syracuse, NY) MATERIALS ENGINEERING TOOLING ALLOYS

9 ANALYSES AND PROPERTIES Typical analysis (standard values in mass-%) Steel designation CPM 3V CPM 9V CPM 10V CPM 15V CPM 420V CPM S 30V CPM Rex M4 CPM Rex 45 CPM Rex T15 CPM Rex 76 CPM Rex 121 C Cr Mo W V Co MECHANICAL PROPERTIES OF CPM MATERIALS /D2 62 HRc /M2 62 HRc CPM 3V 58 HRc CPM Rex M4 62 HRc CPM Rex T15 66 HRc CPM 10V 62 HRc CPM 15V 63 HRc CPM Rex HRc Wear resistance Toughness Data sheets and stock lists for the individual materials can be found at

10 SIGNIFICANT ADVANTAGES OF POWDER METALLURGICAL HIGH PERFORMANCE STEELS POWDER METALLURGICAL STRUCTURE ADVANTAGES 1. ALLOY CONTENT The highest alloy levels can be achieved without any adverse effect on mechanical properties. PM HIGH PERFORMANCE STEEL This fine structure leads to higher cutting edge retention. CONVENTIONAL STRUCTURE 2. TOUGHNESS The uniform distribution of carbide and the absence of metallurgical defects increase impact strength and fracture resistance. 3. WEAR RESISTANCE The overall carbide volume, carbide type, and resulting carbide hardness increase the resistance to abrasive and adhesive surface stresses. 4. GRINDABILITY As the small globules of carbide can be more easily undercut, the machinability and grindability is significantly enhanced. CONVENTIONAL HIGH SPEED STEEL Carbide clusters on the blade can lead to chipping. 5. DIMENSIONAL STABILITY Powder metallurgical steels are free of macro segregation. This leads to more uniform size change and appreciably higher dimensional stability. Tools need less finishing after the heat treatment. 6. DEGREE OF PURITY Micro-cleanliness results in excellent polishability and outstanding EDM properties MATERIALS ENGINEERING TOOLING ALLOYS

11 CPM AND ASP FOR COLD WORKING APPICATIONS EXAMPLES APPLICATION Type of tool Cutting punch Sinter press stamp (calibration) Precision cutting punch Embossing stamp Sinter press tool Die cutting tool Precision cutting punch Produktionsmaterial Cu-Be, s = 0.28 mm Iron powder D 7 Density 7.1 kg/dm 3 St 52, s = 8.0 mm 550 MPa St 2k, s = 1.2 mm 500 MPa Iron powder Density 6.85 kg/dm 3 QStE 460 TM, s = 2.0 mm 800 MPa 16MnCr5, s = 4.5 mm 550 MPa Material CPM 10V PM CPM 10V CPM Rex M CPM 3V PM CPM 9V TiCN ASP ASP 2005 Hardness [HRc] Performance 75,000 parts before regrind 1,500,000 parts before regrind 54,000 parts 75,000 parts 20,000 parts before regrind 60,000 parts before regrind 25,000 parts before regrind 300,000 parts before regrind 5,000 parts 10,000 parts 310,000 parts 150,000 parts to regrind 500,000 parts to regrind 80,000 parts to regrind 190,000 parts to regrind ECONOMIC ATTRACTIVENESS Tool Machine Production material Value of production run Type of steel Material costs Total tool costs Material cost proportion Quantities per regrind Number of regrinds Costs per regrind Max. number of parts per tool Two further tools required Additional regrinding costs (30 x 150) Costs of production run Cutting Die Stamping press St 37 thickness 0.5 mm 8,000,000 parts /M2 80 4, % approx. 150, approx. 2,250,000 8,000 4,500 18,750 CPM 10V 360 4, % approx. 500, ,000, ,530

12 TOOL STEELS COLD WORKING Typical analysis (standard values in mass-%) Mat. no. DIN DIN EN ISO 4957 X210Cr12 X153CrMoV12 X210CrW12 60WCrV8 55NiCrMoV7 45NiCrMo16 90MnCrV8 C Mn Cr Mo V W Ni 1.8 Co HOT WORKING Typical analysis (standard values in mass-%) Mat. no. DIN DIN EN ISO 4957 X37CrMoV5-1 X40CrMoV5-1 C Mn Cr Mo V W Ni Co PLASTIC MOULDING Typical analysis (standard values in mass-%) Mat. no. DIN DIN EN ISO 4957 X38CrMo16 C Mn Cr Mo V W Ni Co + S + Al MATERIALS ENGINEERING TOOLING ALLOYS

13 HIGH SPEED STEEL Typical analysis (standard values in mass-%) Mat. no. DIN DIN EN ISO 4957 HS HS HS 6-5-2C C Mn Cr Mo V W Ni Co 10.5 ZAPP SPECIALTY MATERIALS Zapp brand name VC 800, US 2000, Z-Wear PM (US 200 MC), Z-Tuff PM WAZ330 WAZ450 CSM 21 LC 200 N LC 185 MP Characteristics Cold working steels Hot working steels Plastic mold steel, maraging steel High corrosion resistance up to 60 HRc with outstanding toughness properties Nitrogen-alloyed, high corrosion resistant matrix steel with an excellent polishability and toughness Typical areas of application Cutting and blanking of thick plates/sheets, cutting and blanking tools, cutting, stamping, forming Extrusion tools, forging dies, die inserts Plastic moulds, corrosion resistant construction parts, onstruction parts Knives and wear parts for the food industry and plastic molding. Ideal for highly stressed components, such as pumps and extruders. Highly/mirror polished plastic moulds, mirror polished plastic moulds for optical glass and projectors, flat dies in the plastic extrusion, plastic moulds for discs, extrusion dies for plastic profiles

14 SERVICES AND SPECIAL DESIGNS OUR PRODUCTS GET TO YOU AS QUICKLY AS POSSIBLE THANKS TO a large, well stocked warehouse, 2. modern machinery for processing. Zapp s service center is fully stocked with the largest inventory of powder metallurgical ASP and CPM high performance steels available from one location. We also stock specialty materials and approximately 1,000 tons of conventionally produced tool steels. Hardened EDM blocks are also part of our product range. With our modern machinery, we can meet your processing requirements in a wide range of dimensions of round and flat dimensions. Zapp has a worldwide distribution network and our own Service Centers in Unna/ Germany, Charleston/USA, Gurnee/USA, as well as in Taicang/China. PROCESSING OPTIONS By means of our own grinding and milling technology, it is possible to deliver milled and ground semi-finished products or to manufacture production parts based on drawings according to customer specifications MATERIALS ENGINEERING TOOLING ALLOYS

15 LOGISTICS AND QUALITY QUALITY WITHIN 24 HOURS As one of the largest stockholders for powder metallurgical materials in Europe, we increase your security of supply while providing short and reliable delivery times. By default, the material leaves our Service Center within 48 hours. We provide a wide range of materials in all product forms for you. This brochure gives you information about the most common materials, characteristics and typical applications. You can find detailed material data sheets and stock lists at Interested? We look forward to your call at QUALITY ASSURANCE Our entire company worldwide is certified according to ISO Internal audits ensure the stability of the processes. Numerous customer audits and supplier awards from various sectors confirm our efforts.

16 SERVICE CENTER Zapp Materials Engineering GmbH TOOLING ALLOYS Zapp-Platz Ratingen P.O. Box Ratingen Germany Phone Fax toolingalloys@zapp.com Zapp Tooling Alloys, Inc. 475 International Circle Summerville, South Carolina USA Phone Fax toolingalloys@zapp.com Zapp Materials Engineering GmbH TOOLING ALLOYS Hochstraße Unna P.O. Box Unna Germany Phone Fax toolingalloys@zapp.com Zapp Tooling Alloys, Inc St. Paul Ave. Gurnee, Illinois USA Phone Fax Zapp Precision Metals (Taicang) Co., Ltd. Ningbo Road 34 Taicang Economic Development Area Jiangsu P.R. China Phone Fax Service Centers Sales Offices: ME TA/E/06.17 The technical information, illustrations, drawings, dimensional and weight data and other information included in this brochure only serve as description of our products and represent nonbinding average values. They do not constitute quality data, nor can they be used as a basis for any guarantee of quality and durability. The applications shown serve exclusively for illustration purposes, and should not be considered as quality data nor as guarantee of suitability of the materials for certain applications. This cannot substitute a comprehensive consultation on the selection of our products and their use for a specific application. This brochure is not subject to the updating service.