Leader in superior tooling solutions ASSAB AUTOMOTIVE CONCEPT

Leader in superior tooling solutions ASSAB AUTOMOTIVE CONCEPT

About ASSAB ASSAB was formed in 1945 to market high quality tool steel from Sweden, renowned for its remarkable standards. Headquartered in Singapore, ASSAB has close to 50 sales offices in Asia Pacific supplying the best steel available in the market. Coupled with its best-in-class metallurgical tooling services and technological know-how, ASSAB is both the pioneer and the leader in tool steel solutions in Asia. Since its establishment over 30 years ago, ASSAB Indonesia today is the leading foreign distributor of quality tool steel and services with more than 100 employees operating in service centres and sales offices in Jakarta, Cikarang, Surabaya, Semarang and Medan. Together, they provide one-stop integrated tooling solutions backed by a suite of service capabilities which include machining, heat treatment and metallurgical services. It also stocks a full range of steel suitable for wide spectrum of applications: plastic moulding, die-casting, stamping, pressing, rolling, forming, blanking and hot work. ASSAB anchors the distribution network for Uddeholms AB a leading Swedish mill with more than 300 years of experience in the tool steel industry. The two companies together service leading multinational companies (MNCs) across practically all key industrial sectors in more than 100 countries. ASSAB Automotive Concept 3 Car Body Die for Advanced High Strength Steel 5 Fine Blanking Technology 6 Powder Compacting 7 High Pressure Die Casting 9 Hot Stamping 12 Precision Forging 15 Automotive Lighting 17 Value-Added Services 18 ASSAB is a trademark of ASSAB Pacific Pte Ltd. The information contained herein is based on our present state of knowledge and is intended to provide general notes on our products and their uses. It should not therefore be construed as a warranty of specific properties of the products described or a warranty for fitness for a particular purpose. Each user of ASSAB products is responsible for making its own determination as to the suitability of ASSAB products and services. Edition 150921 2

ASSAB Automotive Concept Today s automotive manufacturing industry continues to face growing challenges as it strives to produce cars that are both stronger and safer while being lighter and consuming less fuel. There is also the constant pressure among Original Equipment Manufacturers (OEMs) for new models to be launched quickly and at competitive prices. The ASSAB Automotive Concept is designed to offer OEMs, Tier 1 suppliers, tool users and tool makers alike, ways to meet these high tooling demands at reduced production costs. ASSAB is continually working with key industrial partners to innovate tooling solutions for high pressure die cast products, Advanced High Strength Steel (AHSS) parts, intricate fine blanked and powder compacted components as well as plastic moulded parts for cars. With its extensive experience and strategic alliance with major car manufacturers and suppliers, ASSAB is well placed to provide quality consultancy on choosing the right tool steel and value-added service for the most demanding automotive part requirements. POWDER COMPACTING Gear VANCRON 40 VANADIS 4 EXTRA CALDIE INJECTION MOULDING Interior Parts NIMAX STAVAX ESR HOT STAMPING Structural Parts QRO 90 SUPREME DIEVAR HIGH PRESSURE DIE CASTING Body Structure Applications DIEVAR VIDAR 1 ESR COLD FORMING Seating systems ASSAB 88 CALDIE VANADIS 4 EXTRA INJECTION MOULDING Head Light MIRRAX ESR VIDAR 1 ESR FINE BLANKING Brake Parts CALDIE VANADIS 4 EXTRA ASSAB 88 HIGH PRESSURE DIE CASTING Engine Block DIEVAR VIDAR 1 ESR 3

New tooling solutions for new materials 4

Car Body Die for Advanced High Strength Steel Advanced High Strength Steel (AHSS) offers many environmental advantages. With increasing demands on the reduction of CO 2 emissions, the lighter weight and higher strength of AHSS makes it ideal for crucial components. The trade-off is that it places higher demands on the tool steel used to form the components. HIGHER DEMANDS ON TOOL STEEL The use of AHSS reduces the amount of materials employed, thereby reducing energy consumption. Previous generations of tool steel are often inadequate to withstand the stresses and failure mechanisms that inevitably follow with the switch to AHSS. This requires a tool steel that is stronger and more ductile for better durability and lower production cost. TOOL STEEL SELECTION MADE EASY Cyclic mechanical loading and sliding contact between the tool and the work material typically results in progressive damages to the active surfaces of the tool. To maintain quality and extend usage, it is necessary to select the best tool steel with suitable properties. ASSAB has a wide range of steel grades to withstand different failure mechanisms, including breakage, abrasive and adhesive wear and chipping. PROPERTY COMPARISON TABLE ASSAB Tool Steel Commonly Used Hardness Chipping and Cracking Resistance Adhesive Wear Resistance Abrasive Wear Resistance Heat Treatment Property Weldability Coating Property ASSAB XW-42 HRC 58-60 ASSAB 88 HRC 58-64 CALDIE HRC 58-62 VANADIS 4 EXTRA HRC 58-64 5

Fine Blanking Technology Safety Belt Seating System Fine blanking technology commonly used in the watch and clock industry is increasingly being employed in the automotive industry particularly for parts with zero-error tolerance. More than 60 percent of fine blanked parts are used in the automotive industry, the majority of which are used to ensure the excellent working condition of critical parts such as the seating system, safety belt, brake system or the airbag. Fine blanking provides finished parts with smooth-cut edges and high precision for their intended function without any additional finishing, unlike normally stamped parts. For quality and precision of the fine blanked parts, the choice of high performance tooling materials is critical due to the complexity of the tools. The right tool steel reduces maintenance cost and production downtime resulting in higher overall productivity. Your Challenge Our Best Solution Our Alternative Solutions Abrasive Wear Adhesive Wear/Galling Plastic Deformation Chipping ASSAB PM60 ASSAB PM30 VANADIS 4 EXTRA VANADIS 4 EXTRA ASSAB PM30 CALDIE ASSAB PM60 ASSAB PM30 VANADIS 4 EXTRA CALDIE VANADIS 4 EXTRA ASSAB PM30 6

Powder Compacting ASSAB s range of steel for powder compacting can increase the lifespan of tools significantly, compared to tools made from conventional tool steel or high speed steel. Achieve superior results in your powder compacting process by using various combinations of ASSAB tool steel with different properties. This in turn will improve quality, shorten production lead time and meet all manufacturing requirements. Furthermore, they are all easy to heat treat and maintain good dimensional stability. CHOOSE THE RIGHT TOOL STEEL ASSAB Tool Steel Chipping and Cracking Abrasive Wear Adhesive Wear Compressive Strength VANCRON 40 VANADIS 4 EXTRA CALDIE UNIMAX 7

Best-in-class for hot work tool steel 8

High Pressure Die Casting Improving tooling economy in high pressure die casting as well as hot forging and hot stamping is one of the key drivers behind developing new grades of tool steel. This development is important to satisfy automotive industry demands for vehicles that are stronger and safer, yet lighter and more eco-friendly. This results in an increased use of Advanced High Strength Steel (AHSS) and high strength aluminium in structural and safety related components. TOOLING MATERIAL FOR HIGH PRESSURE DIE CASTING High pressure die casting offers an economical way of producing large quantities of complex, high tolerance parts in aluminium and magnesium alloys. Long production runs also require dies that last longer. As tooling cost comprises only about 10 percent of the total cost of the finished aluminium die cast product, it is not advisable to cut corners with inferior die steel. Using the most suited tool steel for the specified jobs can in fact favourably influence overall tool performance and reduce long-term maintenance costs. Fewer production interruptions mean higher productivity and greater efficiency. For decades, ASSAB has been bringing to the market tooling solutions for advanced hot work die steel, while offering consultancy on choosing the right steel and service for high pressure die casting technology. QUICK FACTS DIEVAR is a hot work die steel specially developed to provide the best possible performance. It possesses a combination of excellent toughness and very good hot strength, resulting in a superior hot work die steel with excellent resistance to heat checking, corrosion, erosion, gross cracking and indentation. 9

DEMANDS ON DIE STEEL FOR DIE CASTING Die casting dies are exposed to severe thermal and mechanical cyclic loading, which puts high demands on the die material. A number of phenomena is known to restrict die material, the most critical being thermal fatigue (heat checking), corrosion/ erosion, cracking (total failure) and indentation. These phenomena are in turn caused by one or several of these factors: 1. Die material of low quality 2. Unsuitable die design and die making process 3. Improper heat treatment process 4. Insufficient surface treatment 5. Incorrect process parameter adopted for die casting 1. Thermal fatigue (heat checking) 2. Corrosion/erosion 3. Cracking (total failure) SURFACE TREATMENT The surface treatment of the die steel is of great importance. If metallic contact between the die steel and the molten metal can be avoided, the risk of corrosion is much less. An oxide film on the surface provides good protection. Nitrided or nitrocarburized surfaces as well as other coating methods also give a certain protection. Material Loss mg/cm 2 1000 800 600 400 48 HRC Zinc 500 o C Aluminium 735 o C Non-oxidised surface Oxidised surface Brass 950 o C 200 QUALITATIVE COMPARISON OF RESISTANCE TO DIFFERENT DIE FAILURES ASSAB Tool Steel Heat Checking Erosion Gross Cracking Indentation DIEVAR QRO 90 SUPREME 10

DIE ECONOMY As tooling cost makes up about 10 to 25 percent of the total cost of the finished aluminium die cast product, it is important to pay for premium die steel to increase tool life. The most important factors that govern tool life are die material, heat treatment and the die casting process. The tool steel material in a die casting die accounts for 10 to 20 percent of the die cost while the heat treatment cost is about 5 to 10 percent. Application: Die insert for automotive engine block Material: DIEVAR Material hardness: HRC 44-46 Working material: Alloy 380 (Aluminium Alloy) Solution: DIEVAR Die insert steel H13 ESR DIEVAR Die insert life 70,000 shots 130,000 shots ECONOMICAL EVALUATION OF DIE INSERT FOR AUTOMOTIVE ENGINE BLOCK 7000000 6000000 H13 DIEVAR 5000000 TOTAL COST 4000000 3000000 2000000 1000000 0 50000 100000 150000 200000 250000 300000 350000 NUMBER OF PRODUCED PARTS 11

Hot Stamping Advanced High Strength Steel (AHSS) has become a staple of today s modern automotive industry. Environmental requirements as well as higher safety standards make it a key solution for manufacturers aiming for the winning combination of reduced weight and higher strength. Until recently, cold forming was the dominating method for making critical structural components in high strength steel. This has recently been supplemented by hot stamping, the new game-changing technique which places new demands on the tool steel used in the process. TOOL STEEL PROPERTIES Hot stamping tool steel has to be able to withstand specific failure mechanisms involved in hot stamping. Property Good wear resistance at elevated temperature Very good thermal conductivity Good ductility and toughness Enables Abrasion resistance Reduced cycle time with ensured product quality Cracking resistance Excellent machinability Lower tool manufacturing costs Good surface treatment properties Adhesion, abrasion resistance 12

TOOL STEEL SUITED FOR HOT STAMPING ASSAB produces several tool steel grades perfectly suited for tools ASSAB Premium QRO 90 SUPREME Focus on increased thermal conductivity DIEVAR For optimal tool performance UNIMAX Focus on increased wear resistance used in hot stamping. Hot stamping already means a great advantage over traditional production methods. By ASSAB Basic For increased tool performance choosing the right tool steel you can maximise this advantage. Competitive Basic W.-NR. 1.2344 ESR/ AISI H13 Premium STEEL GRADES FOR TRIMMING DIES ASSAB can provide suitable tool ASSAB Tool Steel Abrasive Wear Adhesive Wear Chipping steel with excellent wear and chipping resistance for processes using mechanical trimming dies to VANADIS 4 EXTRA significantly reduce production cost. CALDIE W.-NR. 1.2379/AISI D2 QUICK FACTS The manufacturing of tool steel and customer demand on tool life are important aspects when choosing the right product for use in hot stamping production. 13

Premium tool steel lower costs per part 14

Precision Forging In hot forging, a heated billet is pressed between a die set to form a nearly finished product. Large numbers of solid metal parts are produced in steel, aluminium and copper alloys whose irregular shapes need to be combined with superior die mechanical properties to avoid premature failure. Just as in any other production process that uses tool steel, hot forging requires optimal tool steel properties for better durability of the die. When selecting tool steel for hot forging dies, hardenability, toughness, ductility and temper resistance are some of the most important properties. HRC Formvar H13/1.2344 600 ø C Formvar, specially developed for hot forging, possesses good tempering resistance and hot yield strength to increase tool life over traditional H13/H11 dies. The graph shows how Formvar resists softening at high temperature over time compared to H13, hence providing good resistance against hot wear and plastic deformation leading to longer tool life and cost effective production. H Difference in tempering back resistance between Formvar and H13. TOOL STEEL GRADES PERFECTLY SUITED FOR HOT FORGING The key to choosing a good forging tool steel is to identify the most common problem in any particular die. ASSAB Tool Steel Hot Wear Plastic Deformation Premature Cracking Heat Checking QRO 90 SUPREME UNIMAX DIEVAR ASSAB 8407 2M ASSAB 2714 FORMVAR 15

16 High surface finish in a new light

Automotive Lighting Lower fuel consumption and reduced CO 2 emissions place demands on vehicle weight reduction. This, coupled with short lead time and severe pressure on prices, means that the change from metal to plastic parts is becoming increasingly important. Also increasing are the demands for reinforced higher strength plastic vehicle parts. Parts are also becoming larger and the surface requirements more challenging. OPTIMAL TOOL STEEL LOWERS COST Larger tools require tooling materials with good hardenability to achieve a high degree of toughness after heat treatment. Other properties needed to produce plastic moulds of high quality include high polishability, high corrosion resistance, wear resistance and high thermal conductivity. For best results, select the optimal tool steel for the respective application to maximise tool life and performance, giving the lowest possible total tooling cost per part produced. AUTOMOTIVE LIGHTING Selection of tool steel for plastic moulds in automotive lighting, such as the headlights of a car is of vital importance. The ASSAB product programme for large plastic moulds includes several steel grades perfectly suited for the tough demands of the automotive industry. Vidar 1 ESR for instance, is especially ideal for large moulds requiring a high surface finish, polished or etched and corresponds to the standard preferred grade used for automotive lighting. QUICK FACTS Other steel grades suitable for big moulds in the ASSAB portfolio include Mirrax ESR, and the pre-hardened grades Mirrax 40, Nimax and ASSAB 718. For very high demands on wear resistance, ASSAB s range of powder metallurgical steel grades is also suitable for plastic moulding. REFLECTOR: MIRRAX ESR VIDAR 1 ESR HOUSING: NIMAX ASSAB 718HH LENS: VIDAR 1 ESR MIRRAX ESR NIMAX EXTENSION: VIDAR 1 ESR MIRRAX ESR NIMAX 17

Value-Added Services ASSAB is unmatched as a one-stop product and service provider that offers superior tooling solutions globally. In addition to the supply of tool steel and other special steel, its range of comprehensive value-added services, such as machining and heat treatment, spans the entire supply chain to ensure convenience, accountability and optimal usage of steel for customers. It is committed to achieving solutions for its valued Original Equipment Manufacturer (OEM) partners, with a constant eye on time-to-market and total tooling economy. MACHINING We pre-machine tool steel for the toolmakers to simplify handling and preparation, saving them time and cost. HARDENING AND TEMPERING After hardening, the steel is brittle and needs to be tempered to precise levels that meet specific tooling needs. ASSAB s vacuum hardening process delivers superior steel with minimal distortion and optimum property. SUBZERO TREATMENT A process to enhance wear resistance and dimensional stability of the tools during the service period. OXIDISING For greater durability, oxidising is performed for a surface layer to protect the cavities of aluminium die casting dies from erosion and corrosion attack. 18

NITRIDING In addition to a hard surface layer that is resistant to wear and erosion, a nitrided surface can also increase the corrosion resistance for non-stainless grades. ABP Using the ABP surface treatment, ASSAB is able to considerably extend the service life of die casting and forging dies. TECHNICAL CONSULTING Our corporate philosophy of treating customers as partners means that we are there for you. Whether it be troubleshooting, training or provision of technical literature, we are only a phone call away. More than just selling steel, we provide solutions to overcome any process challenges. We improve customers competitiveness by advising on the use of the right steel to meet specific tooling needs. 19

Choosing the right steel is of vital importance. ASSAB engineers and metallurgists are always ready to assist you in your choice of the optimum steel grade and the best treatment for each application. ASSAB not only supplies steel products with superior quality, we offer state-of-the-art machining, heat treatment and surface treatment services to enhance steel properties to meet your requirement in the shortest lead time. Using a holistic approach as a one-stop solution provider, we are more than just another tool steel supplier. ASSAB and Uddeholm are present on every continent. This ensures you that high quality tool steel and local support are available wherever you are. Together we secure our position as the world s leading supplier of tooling materials. For more information, please visit www.assab.com