Die Casting Tooling Grades

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1 Die Casting Tooling Grades Including an introduction to Die Casting Specifications: NADCA NADCA

2 R&D Research and development play a strategic role at Bohler-Uddeholm. We know that in depth process and material research is the basis for producing the highest quality products. In order to keep up with the constant demand for improved materials, Bohler-Uddeholm maintains a close intensive cooperation with universities and research centers and supports the exchange of information at all levels. The knowledge of our technical experts who are engaged in fundamental research ultimately results in superior value to our customers. Our research activities yield the most modern high performance Tool Steels and High Speed Steels produced by means of Powder Metallurgy production techniques, Aluminum-Alloyed Tool Steels, Nitrogen Alloyed Tool Steels, Electro-Slag Remelted (ESR) and Vacuum Remelted (VMR/VAR) Tool Steels and special products. Pre-tested to give you peace of mind At Bohler-Uddeholm we pre-test our Charpy V-notch toughness levels at our mills in order to ensure that we meet or exceed applicable specifications. By taking this additional step you can be assured that our material will consistently meet your expectations for Bohler-Uddeholm products. Our testing means that customers could consider eliminating additional qualification testing. Keep a sample for future reference and simply test for toughness after heat treatment. This will save you time and money.

3 Heat Treatment Alliance In an effort to continue to add value in our dealings with our customers, we have now created an alliance of world-class heat treaters to support us in our commitment to supplying the World s highest quality tool steels. This alliance will allow us to supply the highest quality steel and assure our customers that the best heat treatment practices are being utilized to enhance the characteristics of our products. Through this partnership we deliver: Enhanced customer service Joint technical support Joint problem solving An unmatched commitment to quality! HEAT TREATING METAL FINISHING

4 NADCA introduced two acceptance levels for AISI H13 for the Die Casting Industry: The Premium Level and The Superior Level. Premium Level NADCA The Premium criteria for H13 material under the NADCA Specification does not deal with the steel making practices or the forging practices of the steel manufacturer. Rather the specification calls for improved levels of cleanliness, a reduction in micro and macro banding, and for certification of impact toughness levels at an 8 ft-lbs. average with a 6 ft-lbs. single minimum value. Combined with NADCA recommended vacuum austenitizing and pressurized gas quenching choosing steels that meet this specification can lead to success in production in the die-casting process. Bohler W302 ISOBLOC meets the Premium Criteria for NADCA BOHLER W302 ISOBLOC (Premium H13) This premium H13 grade is an electro-slag remelted (ESR) steel,and with this process the steel has excellent uniform toughness for hot work applications. W302 ISOBLOC is recommended in applications where there is short term demand on the die material, and heat checking and hot wear are not major factors in the life of the die. Superior Level NADCA When dealing with superior grade H13, the steel making process needs to include secondary refining, either ESR (electro-slag remelting) or VAR (vacuum arc remelting). Additionally the specification calls for improved levels of cleanliness, a reduction in micro and macro banding, and for certification of impact toughness levels at 10 ft-lbs. average with 8 ft-lbs. single minimum value. This type of manufacturing technique combined with NADCA recommended vacuum austenitizing and pressurized gas quenching can lead to success in production where high volume production or critical performance in the die-casting process is required. Uddeholm Orvar Superior and Bohler W302 Superior meet the Superior Criteria for NADCA UDDEHOLM ORVAR (Premium H13) SUPERIOR This H13 was developed to meet the highest criteria for any remelted H13. This steel is produced by a special melting and refining technique in order to give mechanical properties with maximum isotropy and is certified to meet a minimum average Charpy V-notch test result of 10 ft-lbs. at HRC. Suitable for a wide variety of hot work applications, including tools for high pressure die casting, hot extrusion and press forging. Orvar Superior is produced to meet the criteria up to 18 inches in thickness. BOHLER W302 SUPERIOR (Premium H13) This remelted H13 is produced via special melting, refining and forging techniques to possess excellent toughness, making it suitable for demanding hot work applications in dimensions 18 inches and greater in thickness. This material is certified to meet a minimum average 10 ft-lbs. Charpy V-notch at HRC. It is recommended in the larger applications where the maximum properties in an H13 are required.

5 While H13 is good for most general applications in die casting, alternative grades are available that can address specific needs within the die casting environment. NADCA combines the specifications for Premium and Superior Levels of H13 from NADCA , and adds additional controls for other hot work tool steels. All of the alternative grades must be remelted. The Premium Level of H13 is now referred to as NADCA Grade A, and The Superior Level is referred to as NADCA Grade B. Bohler W302 Isobloc meets the requirements of Grade A Uddeholm Orvar Superior and Bohler W302 Superior meet the requirements of Grade B. Grade C: NADCA In applications where higher temper resistance is required, to minimize the loss of hardness at elevated temperatures, there are hot work tool steels available to improve the die s performance. These grades are based on a chemistry, but they have been enhanced to improve performance as a die casting material. Uddeholm Dievar and Bohler W403 VMR meet the requirement of Grade C and are included within NADCA specification. UDDEHOLM DIEVAR Dievar is a high performance chromium molybdenum vanadium alloyed hot work tool steel which is manufactured using the very latest in production and refining techniques. Its unique chemistry and manufacturing process offers an unparalleled combination of resistance to heat checking, gross cracking, hot wear and plastic deformation. Dievar is certified to a minimum, average Charpy V-notch impact toughness of 14 ft-lbs. (19 J) and a minimum unnotched impact toughness of 220 ft-lbs. (300 J) per testing procedures defined in the NADCA documents. For larger cross sections, follow our guidelines for heat treatment. BOHLER W403 VMR Using Vacuum Arc Remelting along with chemistry modification to a standard type alloy, this grade has excellent uniformity in terms of mechanical properties and hot wear resistance. Using a hardening temperature of 1885 F as a standard practice, it can meet the toughness levels of a Superior H13, but have better hot wear resistance. This grade can be special ordered from our mill.

6 Grade D: NADCA In applications when high toughness is required, due to gross cracking or heat checking issues, but temper resistance is not as critical, an H11 type alloy can be considered. These hot work tool steels have a capability requirement of 14 ft-lbs. minimum average Charpy V-notch toughness at HRC. These grades are also required to be remelted, which further adds to the overall uniformity of the product. Bohler W300 Isobloc and Uddeholm Vidar Supreme meet the requirements of Grade D and are included within the NADCA specification. *These grades are special order from our mills. Grade E: NADCA This category of hot work tool steels contains those grades which have been modified to enhance the characteristics of the H11 type alloy. Therefore, these grades are modifications to that alloys contained in Grade D. Further enhancing the toughness of the H11 family, these grades contain some of the toughest hot work tool steel grades. Modifications to the refining process through enhanced remelting, and the chemistry changes make this possible. Bohler W400 VMR and Uddeholm Vidar Superior meet the requirements of Grade E and are included within the NADCA specification. BOHLER W400 VMR Using Vacuum Arc Remelting along with chemistry modification to a standard H11 type alloy, this grade has excellent uniformity in terms of mechanical properties. Using a hardening temperature of 1810 F as a standard practice, it can meet Charpy V-notch toughness values for capability at HRC of 18ft-lbs. Our internal testing shows even higher values making this the toughest hot work tool steel we produce. UDDEHOLM VIDAR SUPERIOR Using pressurized ESR for remelting, along with chemistry modifications to a standard H11 type alloy, this grade has capabilities much like that of DIEVAR in toughness criteria. *This grade can be special ordered from our mill. Other Tooling Material Choices UDDEHOLM QRO 90 SUPREME QRO 90 Supreme is a premium remelted hot work tool steel with very good strength and hardness at elevated temperatures. It has excellent heat transfer characteristics. It is used in smaller dies for brass casting, or in small dies in aluminum die casting where the temperatures run high during production, and cracking is not a concern. BOHLER W360 ISOBLOC W360 Isobloc is a remelted hot work tool steel which can be heat treated to a maximum hardness level of 58 HRC. It is recommended for use in applications where hot wear resistance and/or resistance to plastic deformation is required. One such application is in zinc die casting, where a hardness higher than 52 HRC is required, and inserts in aluminum die casting where erosion is the major issue.

7 Properties Comparison Die Casting Hot Work Tool Steels Automotive Specifications In addition to specifications such as those created by NADCA, many automotive OEM s and other industry leading organizations have crafted their own unique specification requirements. Bohler-Uddeholm meets or exceeds many of these specifications and a sampling of the specifications for which we have qualified material is listed here. Die-Casting Specifications: Aallied Die Casting Amcan Castings Limited Blue Ridge Pressure Castings, Inc. Briggs and Stratton Corp. Burlington Technologies Inc. DaimlerChrysler Eastern Die Casting Inc. Ford Motor Company Ganton Technologies Inc. General Motors Powertrain Group Gibbs Die Casting Corp. J.L. French Corp. Madison Kipp Corp. Magnesium Products Metalloy PHB Tool and Die SPX Contech Toral Cast

8 USA 4902 Tollview Drive Rolling Meadows, IL Sales: Tel: (800) , Bohler-Uddeholm Corporation BU 100 Rev: 10/13/06

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