TOOLING MATERIALS

Required Properties: Depending upon the application, tool steels require

a combination of all or some of the following properties. 1.Strength 2.Hardness 3.Wear Resistance 4.Machinability 5.Toughness 6.Hot hardness 7.Corrosion resistance

The above mentioned properties can be obtained by adding the alloying elements like Carbon, Tungsten, Chromium, Vanadium, Molybdenum, Silicon, Nickel, Manganese, Copper, Cobalt etc to the base metal.

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Effects of Alloying Elements:

Carbon
* >0.6% for normally alloyed steels assures hardenability. * Up to 1.3% it increases hardness, brittleness slightly and wear resistance considerably. *It improves hardenability and together with high carbon improves wear resistance and toughness. *High chromium percentage increases hardening temperature and affects the grindability. It also increases corrosion resistance. *It increases hot hardness. *It doesnt form carbide and thus provides toughness. *It is needed as deoxidizer and improves the hot-forming properties of the steel and also increases machinability. * Generally for tooling steels, it is kept below 0.3%.

Chromium

Cobalt
Silicon

Tungsten

*It improves Hot hardness. *It forms hard abrasion resistance carbides, thus improving the wear resistance.

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Vanadium

*It refines the carbide structure and thus improves forgeability. *It has a very strong tendency to form a hard carbide, thus improves hardness, and wear properties. * Large amount of vanadium carbide causes low grindability. Hence it is kept not usually more than 1%.

Nickel

Generally in combination with other alloying elements, particularly chromium, nickel is used to improve the toughness, corrosion resistance and to some extent, the wear resistance of tool steels.
*To about 0.60%, manganese is added for reducing brittleness and to improve forgeability by nullifying the effects of sulpher. It also provides very good machinability. *Larger amounts of manganese improve hardenability, thus reducing deformation.

Manganese

*In small amounts, it improves deep hardening and toughness. Molybdenum *It is used often in larger amounts in certain high-speed tool steels to replace tungsten.

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Chemical composition of Commonly used Tooling materials:

C A2 D2 O1 S7 4140 4150 P 20 8620 1060 6150 0.95-1.05 1.40-1.60 0.85-1.00 0.45-0.55 0.38-0.43 0.48-0.53 0.28-0.40 0.18-0.23 0.55-0.65 0.48-0.53 Cr 4.75-5.5 11.0013.00 0.400.60 3.003.50 0.801.10 0.801.10 1.402.00 0.400.60 0.801.10 V 0.150.5 1.10 0.30 0.200.30 0.15 min Ni 0.30 0.30 0.30 0.400.70 Co 1.00 Mo 0.901.40 0.701.20 (W=0.40 -0.60) 1.301.80 0.150.25 0.150.25 0.300.50 0.150.25 Mn 1.00 0.60 1.001.40 0.200.80 0.751.00 0.751.00 0.601.00 0.700.90 0.600.90 0.700.90 Si 0.50 0.60 0.50 0.201.00 0.150.30 0.150.30 0.200.80 0.150.30 0.150.30 Cu 0.25 0.25 0.25 0.25 0.25 P 0.03 0.03 0.03 0.03 0.035 0.035 0.003 0.035 0.04 0.035 S 0.03 0.03 0.03 0.03 0.04 0.04 0.003 0.04 0.05 0.04

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Applications:
A2 D2 O1 4140 4140DCF Trim steels, Lance steels Trim steels, Form steels Wear plates, Pilots, Cam key, Heel Block(O1DCF) Punch Retainer, Cam Gib, Slug deflector, Stock guide, Trim retainer, Lifter bar, Bottoming block, Form pad, Pad window, Binder pad, Gage, Lifter. 4150PHT Lifter Depressor, Transfer pin, Stock Guide, Lift rail, Cam push block, Gage, Standoff, Window 6150 Clamp plate, Anvil, CRS Key, Pad balancer, Sensor Block, Cam stop, Nitro plate, Heel retainer, Bottoming Block, Cam pusher, Filler block, Stop block, Keeper, Nitro cap, Anti rotation pin, Stand off, Lifter pin, Coil feed plate, Riser, Cap, Lifter keeper, Pilot block, Lifter bushing retainer, Die steel (Pilot receiving) HRS Parallels 1060 Strippers or any other plate requiring flame hardening Note: DCF Decarburization Free PHT Pre Heat Treated
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Equivalence of materials: AISI/ BS DIN JIS SAE (UK) (Germany) (Japan) (US)
A2 D2 O1 S7 4150 BA2 BD2 BO1 1.2363 X100CrMoV5-1 1.2379 X155CrVMo12-1

IS (INDIA)
-

Common Names

SKD12 SKD11 SKS3 SCM 5

Air-hardening medium-alloy cold work steel High Carbon, High Chromium Cold work steels Oil hardening cold work steels Shock Resisting Steels Chromium-Molybdenum steels

1.2510 100MnCrW4 1.7228

1.2311 40CrMnMo7

P 20
8620 4140 1060 6150

BP20
En 19 En 47

SNCM21 SCM 4 SUP 10

T50Cr4V2

General Mold Steel

Nickel-Chromium-Molybdenum steel Chromium-Molybdenum steels Carbon steel Chromium-vanadium steel

1.6523 1.7225 1.0601 1.8159

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HEAT TREATMENT OF TOOL STEELS: *What Is Heat Treatment as Applied to Steel?

Heat treatment - as applied to steel - can be defined as the application of heat to change a characteristic or condition of the steel. The amount of heat can be measured by the temperature of the steel being treated. Heat treatment is the process of heating an alloy to a high temperature, soaking at that temperature and then cooling it at a particular rate in order to obtain a desired properties.

*Why Do We Heat Treat Steel?

Steel can be categorized in a variety of manners. The principle alloying element is carbon, which influences the steel's hardness and its mechanical properties. It is necessary to apply heat to steel to enable its condition and mechanical properties to be changed to allow the steel to function either during manufacture or its operating life cycle.

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*What happens to steel when Heat Treated? (See Figure)

*Heat treatment depends to a great extent on the structure of the metal and on the manner in which
the structure changes when the metal is heated and cooled. A pure metal cannot be hardened by heat treatment because there is little change in its structure when heated. On the other hand, most alloys respond to heat treatment since their structures change with heating and cooling. 1. At room temp Structure is BCC. 2. Lower transformation temperature (1333F) (a) The start of phase change from ferrite to austenite (b) Structure changes from BCC to FCC. (c) Magnetic to Non magnetic change occurs. 3.Upper transformation temperature Complete phase change from ferrite to austenite.

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Heat Treatment Processes:

Depending on the Heating temperature, soaking time and cooling rate for a particular alloy, the structure changes and accordingly the mechanical properties. In order to have required mechanical properties, the following major heat treatment processes will be carried.

1.Annealing 2.Normalizing 3.Hardening 4.Tempering 5.Case Hardening

Hardening and Tempering of Tool steels:

*Hardening of steels is done to increase the strength and wear properties. *One of the pre-requisites for hardening is sufficient carbon and alloy content. If there is sufficient Carbon content then the steel can be directly hardened. Otherwise the surface of the part has to be carbon enriched using some diffusion treatment hardening techniques. *Hardening of steel requires a change in structure from the BCC found at room temperature to the FCC found in the Austenitic region. The steel is heated to Austenitic region. When suddenly quenched, the Martensite is formed. This is a very strong and brittle structure. *In order to reduce the brittleness due to sudden cooling, hardening will be followed by tempering process.
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Heat treatment of D2:

1.ANNEAL: Heat to 1650F, soak 1 -1/2 hr/inch of thickness, cool 20F/hr to 900F. Cool down with furnace to room temp. Annealed hardness 220 max. Brinell. 2.STRESS RELIEF: heat slowly to 1200-1250F, soak 2hrs/inch of thickness, slow cool (furnace if possible) to room temp. 3.PREHEAT: Heat to 1250F, hold at this temp until thoroughly soaked. 4.HARDEN: Heat to 1850F, soak for 45-60 min/inch of thickness (minimum) 5.QUENCH: Air quench to 150F. Temper immediately. 6.TEMPER: Double temper is mandatory, three tempers is preferred. Soak for 2hrs/inch of thickness, Air cool to room temp. (Between tempers, Double temper at the range of secondary hardness, 900960F strongly recommended) 7.OPTIONAL SUB-ZERO TREATMENT 8. STRESS RELIEF TEMPER: It is strongly recommended after significant grinding, welding or EDM. (Select temp that is 25 or 50F lower than last tempering temp used)

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Heat Treatment of A2:

1.ANNEAL: Heat to 1650F, soak 2 hr/inch of thickness, cool 40F/hr to 900F. Air cool to room temp. Annealed hardness 235 max. Brinell. 2.STRESS RELIEF: heat slowly to 1200-1250F, soak 2hrs/inch of thickness, slow cool (furnace if possible) to room temp. 3.PREHEAT: Heat to 1200F, hold at this temp until thoroughly soaked. 4.HARDEN: Heat to 1750-1850F, soak for 45-60 min/inch of greatest thickness (minimum) 5.QUENCH: Air quench to 150F. Temper immediately. 6.TEMPER: Double temper is mandatory, three tempers is preferred. Soak for 2hrs/inch of thickness, Air cool to room temp between tempers. 7.OPTIONAL SUB-ZERO TREATMENT 8. STRESS RELIEF TEMPER: It is strongly recommended after significant grinding, welding or EDM. (Select temp that is 25 or 50F lower than last tempering temp used)

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Heat Treatment of 6150:

Annealing: Heat to 1500F (815C), hold 2 hours, slow cool 50F(28C)/ hr max. to 1200F (650C), then air or furnace cool. Hardness BHN 170/201. Stress Relieving Annealed Material: 1100-1300F (595-740C), hold 2 hrs, air cool. Hardened Material: 50-100F (30-55C) below last tempering temperature, hold 2 hrs, air cool. Hardening: (Atmosphere or Vacuum Furnace). Preheat: 1200-1250F (650-675C), equalize. Hardening: 1550-1650F (845-900C), soak 10 to 30 minutes. For vacuum hardening, use the high side of the high heat range and soak times. Quench: Oil quench to hand warm, 150F (65C). Temper immediately. Note vacuum furnaces must have oil quench capability. Temper: Tempering at 400-1200F (205-650C) for 1 hr/inch of thickness thickness(2 hrs min.). Air cool to room temperature.

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Recommended Heat Treatment temperatures for Tool steels:

Material Preheat Temp F O1 4140 S7 P20 D2 1250 1247-1346 1247-1301 1301Approx Hardening Temp F 1454/1499 1508/1598 1751 1508/1544 1850 Tempering Temp F 347/599 806/1292 392-995 392-1112 900-960(Double
tempering is mandatory, triple temper is preferred.)

Quenching Media Oil at 149F Oil Air/oil for sections above 3 Oil/Air Air quench to 150F

A2

1200

1750-1850

500 (Double tempering is Air quench to 150F

mandatory, triple temper is preferred.)

6150

1200-1250

1550-1650

400-1200

Oil quench to 150F

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