COLD WORKING TOOL Steel SLD-MAGIC. New die steel seeking longer mold lifespan and total cost reduction.

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1 OLD WORKING TOOL Steel New die steel seeking longer mold lifespan and total cost reduction. 1

2 oncept is the revolutionary next-generation die steel attaining both extended mold lifespan and outstandingly easy mold fabrication. M: Materials Magic A : Advanced G : Gratifying I : Innovative : old work die steel OLD WORK TOOL STEELS/ Features Wear resistance High hardness of 62HR improves wear resistance by approximately 35%*. Surface treatment Adherence between the coating layer and steel after surface treatment (VD and other methods) is improved by approximately 30%*. Minimal deformation during heat treatment for a reduction of approximately 40%* in dimensional changes. improved by approximately 35%* *Hitachi Metals comparison: omparison against 8%r steel (Hitachi Metals product name:sld8), a modified steel of. Wear resistance increases wear resistance by approx. 35% compared with 8% r steel due to the control of carbide morphology. Ohgoshi-method wear test 8%r steel 10%r steel 62HR 62.5HR 60HR Wear resistance is improved. Relationship Wear resistance Good SLD TM 8%r Steel 10%r Steel TM omparison of Properties (HR) Wear resistance Surface treatment* Toughness Dimensional change by heat treatment SLD- MAGI A A + A 8%r Steel %r Steel ARK1 TM Good A D 60HR Weldability (mm 3 /mm 2.mm) Specific wear volume Excellent A Poor D Work material: SM415 Friction distance: 400m Friction speed: 0.76m/s Load: 67N *Surface treatment properties are based on adherence between the coating layer and steel after surface treatment. 8%r steel and 10%r steel offer improved machinability for better processing that reduces the volume of hard carbides within steel, but are inferior to in terms of wear resistance and galling. 2

3 Scuffing resistance shows no scuffing on Hat Testing simulating practical mold wear phenomena. Observation direction Scuffing Test ead Holding Pressure Initiation point and direction of scuffing Punch Die Work Scuffing Test onditions Press : 80ton ranck Press Velocity V : 40~75spm (19.2~36m/min) Holding Pressure Ps : ~2.4ton/cm 2 Length of Stroke : 60mm Lubricant : Anti-rustoil applied and wiped away Work : High-tensile-strength steel (590MPa) Thickness 1.6mm (No plating) Surface Roughness of the mold: Polished by #1000 (Ra=0.04µm) Appearance of work Sample Schematic of test conditions Scuffing Observation OLD WORK TOOL STEELS/ Surface treatment No scuffing Mold surface Work Surface Mold surface Work Surface can be treated with hard coating (VD, TD treatment etc.) under the same conditions as. improves adherence between the oating Layer by VD method Thickness 8µm 50µm Scuffing coating layer and steel after 3-time surface treatment by approx. 30% when compared with 8%r steel, due to optimum alloy design. Adherence between the coating layer and steel after 3-time VD treatment. Scratch test Improved adherence Adherence Index (=100) Index Weldability shows lower susceptibility of cracking by welding compared with and others. Pre-heating temperture Under ~ ~300 Over 300 Ranking of anti-cracking Welding rod: SKD61 grade φ4.0mm Welding current: 130A (A) : racking occured at 3rd layer : No cracking at 3rd laye r Steel A

4 Toughness is superior to in toughness. It can be used as a countermeasure to chipping and cracking with low temp. tempering. 10R-notched harpy impact value Low temp. tempering High temp. tempering Toughness is higher Low temp.: 200 High temp.: OLD WORK TOOL STEELS/ Fatigue strength shows improved fatigue strength in comparison to due to the control of carbide morphologies. Physical Properties Rotating bending fatigue test (N/mm 2 ) Stress (J/cm 5 ) 10R-notched harpy impact value (61HR) (60HR) ycles (62HR) Thermal expansion coefficient X10-6 / 20~100 20~ Thermal conductivity W/m K Room temperature 28.9 Specific gravity Annealed Quenched and tempered Young's modulus GPa 209 Transformation temperature Ac1 850 Ms temperature 166 4

5 Heat Treatment It is possible to heat treat under the same conditions as. Standard Heat Treatment onditions Annealed 255HW or under Quenching 1010~1040 Air quenching Tempering 480~530 Air cooling or 150~250 Air cooling (HR) 60HR or over Quenched and tempered hardness OLD WORK TOOL STEELS/ It is possible to obtain maximum hardness (60~62HR) with tempering at around 500 where dimensional change is near to zero, achieving both high hardness and less dimensional change. Secular change of after high temp. tempering is almost equivalent to that of, and smaller than 8% r steel. It is possible to reduce secular change via low temp. tempering, sub-zero treatment or stabilizing. (HR) Dimensional change after heat treatment Dimensional change rate (%) Quenching Tempering temperature 2Hr, Twice ( ) Quenching 1030 *A Tempering temperature 2Hr, Twice *A * ( ) *A: Minor dimensional change *: Minor dimensional change with maximum hardness Secular change / Dimensional growth Low temp. tempering High temp. tempering Size of test pieces: 45T X 90W X 200L Austenitizing: 1030 Low temp. tempering: 180 X 2times High temp. tempering: 520 X 2times Measure: 200mm direction Dimensional change after 6 months posterior heat treatment Dimensional change rate (%) 5

6 Heat Treatment The difference of quenching temperature shows stable both high hardness and very little dimentional change at around hardening temperature. (HR) Quenching temperature OLD WORK TOOL STEELS/ To add subzero treatment, can achieve high hardness (62HR) by both high and low temp. tempering. To combine subzero and stabilizing treatment is very effective for reducing secular distortion. shows almost the same decomposition behavior of the retained austenite, as that of conventional. The subzero treatment and hardness (HR) The retained austenite (%) Quenching 1030 subzero ( ) Tempering temperature 2Hr, Twice The retained austenite 50 As quenched ( ) Tempering temperature 2Hr, Twice with subzero without subzero ( ) Tempering temperature 2Hr Twice 6

7 Heat Treatment shows smaller in dimentional change difference in the longitudinal, width and thickness directions, compared to or 8%r steels. Secular change / Dimensional change Small difference between L and W direction Upper L (Longitudinal) Lower W (Width) Dimensional change ratio (%) OLD WORK TOOL STEELS/ shows narrow deviation of dimensional changes by heat treatment, as a result, the better dimensional tolerance can be attained. For example, in case of separation type molds, mold set up time was largely decreased because of narrow dimensional deviation. Deviation comparison of dimensional changes of actual mold after heat treatment. Dimensional chauge by Heat Treatment (%) Standard deviation : Number of measurement : frequency Direction Original Dimension Dimensional hange Standard deviation : Number of measurement : Dimensional hange Ratio Mold set up time frequency Example of dimensional change for insert type mold. W L Narrow deviation (mm) (mm) (%) Wide deviation 54% reduction of mold ajusting time after heat treatment W L (Index) 15 Width Longitudinal 7

8 improves machinability on face mill by over twice that of and by approx. 35% compared to 8% r steel. It also demonstrates superior machinability using other tools. Mold processing time is shortened due to enhanced machinability. The lifespan of cutting tools is increased, thus reducing direct purchasing costs of tools. ø125 Face Mill is improved Work: Annealed condition Tool: oated carbide chip, 1chip only utting speed: 120m/min, Dry Feed: 0.13mm/blade Depth of cut: 2 Z X 90 W mm, utting distance: 4m Tool Wear 0.4 (mm) OLD WORK TOOL STEELS/ End Mill Drill Tool Wear (mm) Work: Annealed condition Tool: End mill ø8 (o-hss) utting speed: 30m/min,Downcut,Wet Feed: 0.05mm/tooth Depth of cut: 15 Z X 0.5 W mm, utting distance: 5m Work: Annealed condition Tool: Drill ø5 (o-hss) utting speed: 20m/min, Wet Feed: 0.05mm/ev Depth of hole: 25mm, 200Holes Tool Wear (mm) ø63 High feed cutter Work: Annealed condition Tool: oated carbide chip utting speed: 150m/min, Dry Feed: 1.3mm/tooth Depth of cut: 1mm, utting distance: 60m Tool Wear (mm) 8

9 can enhance tool lives because of lower cutting tool temperatures. utting tool temperature comparison EPR6080 (ultrafine particle W) (ø8 X 6NT TiAIN) OLD WORK TOOL STEELS/ olor of chips olor of chips Grindability (Tempered color) Grindability of is better than those of and 10% r steel, and almost equivalleut to 8% r steel. Temperature at tool surface ( ) %r 10%r (m) utting Length Grindability comparison as a function of diffenent grinding wheels Grinding Wheel : Alumina Single rystal : Alumina : Alumina + Other ceramics n=3981min-1(v=100m/min) Ap=12mm Ae=0.4mm OH=25mm Dry with Air low KITAMURA M/ 11kw Grinding test conditions Work 50 X 90 X 200L (Heat treated condition) Machine: Reciprocal Type Grinding onditions Wet Traverse Grinding Velocity of Wheel 33m/sec Table velocity 0.33m/sec Undercut 5µm/pass ross Field 5mm/lap Spark out 1lap Total undercut 0.1mm Grinding ratio Ground off amount/wear of wheel Grindability ratio Grinding ratio is higher the better 9

10 Application Examples In addition to prolonging the lifespan of molds, also enables remarkably easy mold fabrication, thereby contributing to total cost reduction and shorter processing times in the automobile and mold industries. 01 ending die for automotive parts Inner parts Work 440MPa (t3.2) Surface treatment 59~61HR VD (Ti) 60~62HR VD (Ti) Scuffing Lifespan ause 1,300 pcs Severe galling 156,000 pcs Less galling Mold lifespan significantly improved OLD WORK TOOL STEELS/ 02 lanking die for automotive parts Function parts Work 590MPa (t7.0) 03 lanking die for electrical appliances Electrical appliances Work Film 04 lanking die for electrical appliances Optical parts Work SP (t0.8) Lifespan ause Lifespan ause Lifespan ause 58~60HR 170 Tempering ad 58~60HR 170 Tempering Good 15,000 pcs Max. 40,000 pcs carrying on Severe chipping Less chipping 58~60 HR 58~60 HR 530 Tempering 530 Tempering ad Good 650,000 pcs 1,020,000 pcs Early wear out Less wear 60~62HR 60-62HR 200 Tempering 480 Tempering ad Good 100,000 pcs 100,000 pcs carrying on urr (Wear out) Reduce wear by half hipping Mold lifespan more than doubles Mold lifespan 50% up Mold lifespan doubles 05 lanking die for electrical appliances Liquid crystal panel parts Work SUS304 (t0.3) Dimensional change Lifespan ause 60-62HR 60~62HR 505 Tempering 480 Tempering 0.05% % 30,000 pcs 40,000 pcs carrying on urr (Wear out) Less wear Mold lifespan 30% up Note: The above-listed data is for application examples only and this data does not assure performance. It is not suited for molds with EDM finished surface that require a high degree of mirror finish such as plastic molds. 10

11 06 Die for hydroforming Exhawst pipe Work Steel tube Distortion by heat treatment 56HR Very hard to adjusting the upper and lower die blocks clue to large dimensional changes ad 58HR Reduction of adjusting time of the upper and the lower die blocks Improved. Adjusting is finished only by one chip used. Mold adjusting time is reduced because of small dimension change of upper and lower die blocks by heat treatment 07 OLD WORK TOOL STEELS/ Die for cold press Automobile parts Work Hight-tensile -strength steel 08 Die for cold press Inner parts Work 440MPa (t2.3) 09 Die for cold press Inner parts Work 780MPa (t2.3) Surface treatment ause Surface treatment Lifespan Problem Surface treatment Problem 58~60HR Large dimensional ohange TD all End Miuing Exchanging chips quite offen 58~60HR TD 5500 pcs Scuffing 59~61HR TD ad Mochinabiliry and dimension change 60~62HR Deviation is reduced to 1/2. Ajusting time is reduced TD The number of exchanged chips is reducedto 1/5~1/10 compared to. Feed rate is increased to 1.7 times. 60~62HR Dimensional hanges by TD is within 5/100 ontinuing beyond 15,000 60~62HR Dimensional hanges by TD is small The life of chips used is 10 times longer than cases. Small dimension deviation Mold Iifespan is improved by almost 3 times. Small dimension changes after TD treatment 10 Die for cold press 59~60HR 59~60HR Deformation of datum plane Adjustment time All 26 pieces deformed over min. 0 min. Only 1 piece out of 26 pieces deformed 0.02mm. Adjustment time is reduced because of redused the number of deformed blocks. Note: The above-listed data is for application examples only and this data does not assure performance. It is not suited for molds with EDM finished surface that require a high degree of mirror finish such as plastic molds. 11

12 Head Office Head Office Other Office Head Office Guangzhou Liaison Office Hitachi Metals, Ltd. SEAVANS North uilding, 1-2-1, Shibaura, Minato-ku, Tokyo , Japan Specialty Steel ompany Hitachi Metals America, Ltd. 2 Manhattanville Road, Suite 301, Purchase, NY 10577, U.S.A. hicago, Detroit, harlotte, San Jose Hitachi Metals Europe GmbH Immermannstrasse 14-16,40210 Duesseldorf, Germany Hitachi Metals Singapore Pte. Ltd. 12 Gul Avenue, Singapore Hitachi Metals (Shanghai) Ltd. 11F, Tian An enter, No.338 NanJing Road (West), Shanghai, , hina ha Shan Town, Dong Guan ity, hina Tel Fax Tel Fax Tel Fax Tel Fax Tel Fax Hitachi Metals(Dong Guan)Specialty Steel o.,ltd. Tel Fax Dalian ranch 3-2, Koushin Mould Industrial Park III F. T. Z. Dalian, hina Tel /1022 Fax Tianjin ranch eijing Liaison Office No.13 Workshop, Wenxin Industrial Park, Jingxiang Road, Xiaodian Town, eichen Economic Development Zone, Tianjin, hina Hitachi Metals, Ltd. Room No.1418, eijing Fortune uilding,5 Dong San Huan ei-lu, haoyang District, eijing, hina Tel /3102 Fax Tel Fax The characteristics listed on this catalog are representative values and they do not guarantee the quality of the product. This catalog and its contents are subject to change without notice. Do not duplicate this catalog without permission from Hitachi Metals,Ltd. Please contact a representative of our Specialty Steel Division if there are any questions or problems. Our address and contact indicated in this catalog are those as of March If you cannot put a call through, please contact our orporate ommunication Group. in Tokyo below. Tel: Fax: hmcc@hitachi-metals.co.jp March 2010 (PDF)