STEELS FOR HOT WORK APPLICATIONS

Torbjrn Spngberg, Olle Tnnberg, Bengt Klarenfjord, Uddeholm Tooling AB

Hot work

Plastics

HPS

Cold work

Torbjrn, Olle, Bengt, Rally 2008

Hot work applications

h Die casting

h Extrusion

h Forging

Torbjrn, Olle, Bengt, Rally 2008

Typical failures in hot work applications

Heat checking ( thermal fatigue ) Gross cracking

Erosion / Hot wear

Soldering

Torbjrn, Olle, Bengt, Rally 2008

The demand on the die steel

Torbjrn, Olle, Bengt, Rally 2008

Important die steel properties

Temper resistance Hot yield strength Creep strength Thermal expansion Heat conductivity Ductility / Toughness

Torbjrn, Olle, Bengt, Rally 2008

For a good performance you need both a good die steel and a good heat treatment

Torbjrn, Olle, Bengt, Rally 2008

Uddeholm hot work programme

ALVAR ALVAR14 14 ALVAR ALVAR ORVAR ORVAR2 2Microdized Microdized VIDAR VIDAR1 1 ORVAR ORVARSUPREME SUPREME ORVAR ORVARSUPERIOR SUPERIOR VIDAR VIDARSUPERIOR SUPERIOR QRO QRO90 90SUPREME SUPREME HOTVAR HOTVAR DIEVAR DIEVAR UNIMAX UNIMAX

Torbjrn, Olle, Bengt, Rally 2008

Steel C ALVAR ALVAR 14 VIDAR 1 VIDAR SUPERIOR ORVAR 2M ORVAR SUPREME ORVAR SUPERIOR DIEVAR UNIMAX QRO 90 SUPREME HOTVAR
9

Chemical composition % Si 0,7 0,3 1,0 0,3 1,0 1,0 1,0 0,2 0,2 0,3 1,0 Mn 0,8 0,7 0,4 0,3 0,4 0,4 0,4 0,5 0,5 0,8 0,8 Cr 1,8 1,1 5,0 5,0 5,3 5,2 5,2 5,0 5,0 2,6 2,6 Ni 0,6 1,7 Mo 0,3 0,5 1,3 1,3 1,3 1,4 1,4 2,3 2,3 2,3 2,3 V 0,2 0,1 0,4 0,5 0,9 0,9 0,9 0,6 0,5 0,9 0,9

0,45 0,55 0.38 0,36 0,39 0,39 0,39 0,35 0,50 0,38 0,55

Torbjrn, Olle, Bengt, Rally 2008

PRODUCTION LINE

ESR Electric arc furnace Control / Inspection Ladle furnace Machining Vacuum Up-hill casting degasing

Homogenizing treatment Test certificate Heat treatment

Forging

Rolling

Warehouse

10

Torbjrn, Olle, Bengt, Rally 2008

Process development
20

Total oxygen content (ppm) and toughness, KV, (J)

15

Toughness

10

Remelting under protected atmosphere

Oxygen content

0 1988

1990

1992

1994

1996

1998

2000

Special heat treatments

11

Torbjrn, Olle, Bengt, Rally 2008

Microstructural influence on the ductility

12

Torbjrn, Olle, Bengt, Rally 2008

Test certificate
Chemical composition Microcleanliness Annealed microstructure and hardness As quenched hardness and grain size Impact toughness Ultrasonic inspection

13

Torbjrn, Olle, Bengt, Rally 2008

Effect of time on hardness at 600C ORVAR SUPREME and ALVAR 14

45 40 35 30

HRC

25 20 15 10 5 0 2 5 15 65 100 h

ORVAR SUPREME ALVAR 14

14

Torbjrn, Olle, Bengt, Rally 2008

Effect of time on hardness at 550 C

60 55 50 45 40 35 30 25 20 1 10 hours 100

ORVAR SUPREME QRO 90 SUPREME HOTVAR VIDAR SUPERIOR

15

Torbjrn, Olle, Bengt, Rally 2008

HRC

Effect of time on hardness at 600C

60 55 50 HRC 45 40 35 30 25 20 1 10 hours
16

ORVAR SUPREME QRO 90 SUPREME HOTVAR VIDAR SUPERIOR

100

Torbjrn, Olle, Bengt, Rally 2008

Yield strength at elevated temperatures

HOTVAR, 58 HRC; QRO 90 SUPREME, 48 HRC; ORVAR SUPREME, 53 HRC; VIDAR SUPERIOR, 45 HRC; DIEVAR, 47/48 HRC

MPa

1100 900 700 500 300

550 575 600 650 Temperature C

ORVAR SUPREME VIDAR SUPERIOR

QRO 90 SUPREME DIEVAR

HOTVAR

17

Torbjrn, Olle, Bengt, Rally 2008

Toughness at elevated temperatures centre and short-tranverse direction

Charpy V, J
140 120 100 80 60 40 20 0 20
18

DIEVAR 45 HRC

ORVAR SUPREME 45 HRC QRO 90 SUPREME 45 HRC VIDAR SUPERIOR 45 HRC

100

200

300

400

500

C
Torbjrn, Olle, Bengt, Rally 2008

Toughness at elevated temperatures centre and short-transverse direction

Charpy V, J
140 120 100 80 60 40 20 0 20
19

DIEVAR 38 HRC

DIEVAR 45 HRC

DIEVAR 47 HRC 100 200 300 400 500

C
Torbjrn, Olle, Bengt, Rally 2008

Testing of creep resistance

20

Torbjrn, Olle, Bengt, Rally 2008

Creep testing at 550C and 500MPa

6

Strain [%]

H13
3

Hotvar

Dievar

QRO 90 Supreme 1030C

2

0 0 100 200 300 400 500 Hours 600 700 800 900 1000

21

Torbjrn, Olle, Bengt, Rally 2008

Testing of heat checking

Air

22

Torbjrn, Olle, Bengt, Rally 2008

Heat checking test result

220

20-700C/air/800 cycles
200 180

DIEVAR ORVAR SUPREME

T A =1025C/30min

Max sprickdjup (um)

160 140 120 100 80 60 40 20 0 40 42 44 46 48

50

52

Hrdhet (HRC)
23

Torbjrn, Olle, Bengt, Rally 2008

Min toughness values in short-transverse direction at 44 46HRC

Charpy V
20 18 16 14 12 10 8 6 4 2 0 Min toughness values

ORVAR SUPREME ORVAR SUPERIOR VIDAR SUPERIOR DIEVAR

24

Torbjrn, Olle, Bengt, Rally 2008

Rersistance to hot wear, plastic deformation and thermal fatigue

Product mapping
HOTVAR

QRO 90 SUPREME UNIMAX DIEVAR ORVAR 2M VIDAR 1 ORVAR SUPERIOR ORVAR SUPREME VIDAR SUPERIOR

ALVAR 14/ALVAR

Resistance to cracking
25

Torbjrn, Olle, Bengt, Rally 2008

ALVAR 14 / ALVAR

Application areas eg support tools in extrusion and also forging dies

26

Torbjrn, Olle, Bengt, Rally 2008

ORVAR 2 Microdized VIDAR 1

Typical application area is Al-extrusion. Dies and components.

27

Torbjrn, Olle, Bengt, Rally 2008

ORVAR SUPREME / SUPERIOR

Used in hot work applications as an universal steel grade. Die casting and forging.

28

Torbjrn, Olle, Bengt, Rally 2008

VIDAR SUPERIOR

Used in die casting and forging.

29

Torbjrn, Olle, Bengt, Rally 2008

DIEVAR

Used in die casting and forging when the demands on hot strength and ductility/toughness are high.

30

Torbjrn, Olle, Bengt, Rally 2008

DIEVAR

Customer benefits Fewer Fewer interruptions interruptions in in production production Better Better surface surface quality quality of of produced produced parts parts Increased Increased die die life life Possibility Possibility for for producing producing larger larger parts parts Possibility Possibility for for larger larger multi-cavity multi-cavity dies dies Longer Longer running running periods periods between between maintenance maintenance work work

31

Torbjrn, Olle, Bengt, Rally 2008

QRO 90 SUPREME
Used in small dies , inserts and cores. Eg brass die casting and forging. Also for hard loaded extrusion dies and components.

32

Torbjrn, Olle, Bengt, Rally 2008

HOTVAR
Used in applications where hot wear or plastic deformation are the dominating failure mechanisms. Eg small forging dies.

33

Torbjrn, Olle, Bengt, Rally 2008

UNIMAX
Recommended in hot work applications where high hardness in combination with high ductility and toughness are needed. Eg Mg - die casting, forging dies and large extrusion dies.

34

Torbjrn, Olle, Bengt, Rally 2008

The Cost Iceberg

Visible costs

Material / heat treatment Die making

Hiden costs

Maintenance Interruptions in production Less availability in production line Less after-treating of parts Delivery delays

35

Torbjrn, Olle, Bengt, Rally 2008

Trends in hot work and demands on tool steels

Larger dies needed with highest quality for long run production Better wear resistance Improved hardenability Improved ductility and toughness Improved strength at elevated temperatures

36

Torbjrn, Olle, Bengt, Rally 2008

TRUST IS SOMETHING YOU EARN, EVERY DAY.