DIE STEELS FOR DIE CASTING DIE STEELS FOR DIE CASTINGDAC

DIE STEELS FOR DIE CASTING DIE STEELS FOR DIE CASTINGDAC

DIE STEELS FOR DIE CASTING DAC Series In compliance with changes of die casting technology 1 YSS Correlation for Diecasting Die steels High In co...

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DIE STEELS FOR DIE CASTING DAC Series In compliance with changes of die casting technology

1

YSS Correlation for Diecasting Die steels

High

In compliance with diversification of diecasting technology, variety of steel grade is prepared in order to best fit for each individual application.

YXR33

For ejector pins

High temperature molten alloy High strength at high temperature

DAC10 Strength at high temperature

DIE STEELS FOR DIE CASTING / DAC Series

DAC45

DAC55

Strength toughness

Isotropy

FDAC

DAC

SKD61

Prehardened steel

E-DAC

Standard die steel

HPM7

Toughness

High

Die Steel for Diecasting Die-Kind and Features Applications Die for Aluminium/Zinc Alloy in general use

High efficiency die, Squeeze die

Steel Brand

Features

DAC

Strength at elevated temperature and toughness are well

equivalent to JIS SKD61

balanced. Good machinability and less deformation after

0.38C-5Cr-1.3Mo-1V

heat treatment.

DAC55

Superior heat crack resistance. Higher toughness enables initial hardness of dies much

5Cr-Mo-V-Ni-Co

higher.

DAC10

Higher strength at elevated temperature and good heat

5Cr-2.5Mo-V

crack resistance.

Die for high melting point aluminium

DAC45

Higher strength at elevated temperature.

alloy and copper alloy

3.5Cr-W-Mo-V

Good crack development resistance.

YXR33

Highest strength at elevated temperature.

Matrix HSS

Best erosion resistance.

FDAC

Standard hardness is 40HRC.

Precision Die Cast Die

Longer life pin, insert die parts

Die for small lot, Simple die

Simple die Core, Backblock

SKD61+S

Sulphurized DAC

Delivered prehardened.

HPM7

Prehardened to 32HRC.Good machinability & Toughness. Least difference of hardness between surface and center

Mn-Cr-Mo

of large mold.

2

Appearance of Heat Crack and Test Result Heat crack

Appearance

Cross Section

Diecast in general use On the flat surface of dies Network Temperature of molten material

DIE STEELS FOR DIE CASTING / DAC Series

0.1mm

0.1mm

Precision/Hi-Si Al-alloy Diecast On the edge of dies Crack openning Temperature of molten material 50mm

0.1mm

Diecast in SQ use At the corner of dies Stress concentration Temperature of molten material

0.4mm

Number of cycles of heat crack initiation and cross sectional appearance Test: Repetition of Heating upto 600°C by high frequency and Cooling by spray water. Specimen used is one end of dia 90mm bar.

No. of test cycle Steel Brand HRC

DAC

43

DAC

47

1000

Occurance of heat crack

DAC

51

DAC10

47

DAC55

50

DAC55

53

cycle 2000

3000

Observation of heat crack

3

Cross sectional appearance

0.5mm

Mechanical Properties Tensile Strength at elevated temperature (N/mm2) (MPa) 1,800

170

1,600

160

1,500

140

1,300

130

1,200

Quench 1,020°C x 30min Half Temperature Time 30 min. Oil Cooling

44HRC Tensile Strength

150

1,400

Tensile Strength

Tempering Hardness 50HRC

180

1,700

40HRC

120

1,100

110

1,000

100

900

90

800

80

700

70

600

60

500

50

400

40

300

30 20 100

200

300

400

500

600

700

Testing Temperature X 10min.

Tempered hardness vs Tensile Strength at elevated temperature 1400 Tensile Strenght at elevated temperature (N/mm2)

Tempered hardness vs Charpy I - Value 70

600°C

DAC55

1200

60 DAC55

DAC10

1000 800

DAC

600

2U Charpy Impact Value (J/cm2)

DIE STEELS FOR DIE CASTING / DAC Series

(kgf/mm2)

YXR33 DAC45

DAC10

400

DAC55

DAC

200

DAC10

DAC55

50

DAC

DAC DAC45

40 DAC10

30

Quench Cool Speed solid line:oil cool dashed line:half temperature time 30min

20 10

700°C 0

0 40

45

50 Hardness (HRC)

55

60

40

42

44 46 Hardness (HRC)

48

50

Physical Properties Thermal Expansion Coefficient X 10-6/ °C Thermal Conductivity W/m·K[cal/cm·s·°C]

Temperature

DAC

DAC10

DAC55

DAC45

YXR33

100°C

11.7

10.7

11.6

10.5

11.6

700°C

14.0

13.2

13.7

13.6

13.2

20°C

30.5 [0.073]

32.2 [0.077]

34.5 [0.082]

26.4 [0.063]

27.2 [0.065]

700°C

28.0 [0.067]

28.5 [0.068]

28.0 [0.067]

27.6 [0.066]

29.7 [0.071]

4

DAC

Quenched & tempered hardness 60

DAC Standard Quality for Aluminium Diecasting

50 Hardness (HRC)

DAC (Quench 1,020°C HTT 30min)

40

30

20

Features

10 500 550 600 as quenched 400 Tempering Temperature (°C)

*Good balance of both strength at elevated temperature and toughness. *Good machinability with less deformation after heat treatment.

650

700

Standard Heat Treatment Process

Applications

1,000 ~1,050°C

Quench

*General die for Aluminium Diecasting. *Die for Zinc Diecasting. *Die for low pressure casting.

Forced Air Cooling High Pressure Gas Cooling etc.

750 ~800°C

(Remarks) Both forged and cast steel available for low pressure casting die with prehardened condition of 30-40HRC.

500 ~550°C Second Pre -heating

First Pre -heating

Hardend hardness 45~48HRC general size dies. 43~46HRC big size dies.

Austeniti -zation

300 ~350°C

Quench cooling speed and Microstructure (X400) Oil cool

Air Cooling

Tempering

Pre -heating

Half Temperature Time (30min.)

To Tempering Furnace 100~150°C

550~680°C

Temper

Room Temperature

Tempering is required at least two times or more.

Tempered hardness vs Charpy I-Value (J/cm2) (kgf·m / cm2) 80 8

Half Temperature Time (60min.) Quench Temperature 1020°C Hardness 44HRC

2U Charpy I-Value

DIE STEELS FOR DIE CASTING / DAC Series

DAC is most widely used as Die for Aluminium and Zinc Diecasting. DAC is hot working tool steel with good balance of strength, toughness and heat resistance. With introduction of Isotoropy technology DAC has become tougher and more isotropic to help life of dies longer and stable.

5

70

7

60

6

50

5

40

4

30

3

20

2

10

1

0

0

1,020°C

Oil cool Half Temperature time 15min 30min 45min 60min

40

44 48 Hardness (HRC)

52

DAC55

Quenched & tempered hardness 60

DAC55 For High Performance Diecasting

1020°C

DAC55 has been developed in responding to the needs for a longer die life or a steel with good hardenablity as well as heat crack resistance and toughness for large and medium size dies.

50

Hardness(HRC)

1000°C 45

40

*Good heat crack resistance. *Higher service hardness of 50-53HRC. *Higher resistant to crack development. *Higher strength at elevated temperature. *Good hardenability.

35

30

25

Applications

400

500

as quenched

*Precision diecasting die. *Big and medium dies for diecasting. *Squeeze diecasting die.

550

600

650

700

(°C)Tempering Temp.

Recommended hardness Hardness (HRC)

Standard Heat Treatment Quench 1010-1030°C quick cool Temper 550°C-640°C Hardness 43-53 HRC

Application

50-53

Small / Squeeze Die ( Anti-Heat Crack )

46-50

General Use Die

43-46

Large Die (Priority: Toughness)

(Remarks) Recommended hardness may not apply depending on projection or casting conditions

Quench cooling speed and Microstructure (X 400)

Tempered hardness vs Charpy I-Value Charpy I-Value (kgf·m/cm2)

Half Temperature Time (15min.)

5

DAC55

4

40

DAC

3 2

20

1 0

Half Temperature Time (30min.)

46

48 50 Hardness (HRC)

Charpy I-Value (J/cm2)

6

52

Quench Cool Speed vs Charpy I-Value

Quench Temperature 1020°C Hardness 44HRC

(Test Result of 250mm Qubic Block) 50 2mmU Charpy I-Value (J/cm2) T-Direction

DIE STEELS FOR DIE CASTING / DAC Series

Features

Oil cool

Quenching temperature 1040°C

55

40

30

DAC (45HRC)

20

10

0

6

DAC55 (50HRC)

0

10

20 30 40 Half Temperature Time (min) Cooling Time (1,020°C→520°C)

50

60

DAC10

Quenched & tempered hardness 60

DAC10 For Precision Diecasting

50 Hardness (HRC)

As material of die for diecast products required higher level of surface, and heat crack resistance has been intensified. Most useful for small and medium size dies of their longer life.

30

20

*Higher strength at elevated temperature and good heat crack resistance. *Good erosion resistance.

10

400 as quenched

500

550

600

650

700

Tempering Temperature (°C)

Applications *Small / Medium size dies of which O-ring grooves require heat crack resistance. *Medium dies for products like headcover which requires good appearance. *Small dies for VTR parts or OA components which require erosion resistance.

Quench 1010-1030°C quick cool Temper 570°C-610°C Hardness 44-51 HRC

Quench cooling speed and Microstructure (X 400) Oil cool

(1020°C Quenching)

(J/cm2) (kgf·m/cm2) 80 8

2U Charpy I-Value

Standard Heat Treatment

Tempered hardness vs Charpy I-Value

Half Temperature Time (15min.)

70

7

60

6

50

5

40

4

30

3

20

2

10

1

0

0

Oil cool Half Temperature time 15min

60min 30min 45min

40 44 Hardness (HRC)

48

52

Oil Cool Test Piece Size: 10 X 10 X 55mm

Quench Cool Speed vs Charpy I-Value (1020°C Quenching)

(J/cm2) (kgf·m/cm2) 80 8

Half Temperature Time (30min.) Quench Temperature 1020°C Hardness 44HRC

2U Charpy I-Value

DIE STEELS FOR DIE CASTING / DAC Series

Features

DAC10 (Quench 1,020°C HTT 15min)

40

70

7

60

6

50

5

40

4

30

3

20

2

10

1

0

0

40HRC 44HRC 48HRC 52HRC

Oil cool

7

15

30 HTT: min.

45

60

DAC45

Quenched & tempered hardness 60

DAC45 For Diecasting Al-Alloy containing high Silicon Hardness (HRC)

50

Exclusively developed for dies used in elevated temperature casting of 750°C molten steel. Superb erosion resistance.

30 DAC45 Quench 1,070°C Oil Cooling

20

*Exceptional high strength at elevated temperature. *Higher resistant to crack development.

10

Applications

as quenched

500

550

600

650

700

Standard Heat Treatment Process 1,060 ~1,070°C

Quench

Standard Heat Treatment

750 ~800°C

Quench 1060-1070°C oil cool Temper 570°C-610°C Hardness 47-51 HRC

Oil cool

500 ~550°C First Pre -heating

Quench temperature and Microstructure (X 400) 1060°C

400

Tempering Temp. (°C)

*Die for High Silicon Aluminium Diecasting like ADC14. *Die for Copper Alloy Diecasting. *Erosion resistant pin, insert die parts.

Second Pre -heating

Austeniti -zation

1080°C

100~150°C To Tempering Furnace

570~640°C

Temper 300 ~350°C

Air Cooling

Pre -heating

Tempering

Room Temperature

Tempering is requuired at least two times or more.

Overheat 1100°C

Softening Resistance 50

DAC DAC45 45 650°C 40

Hardness (HRC)

DIE STEELS FOR DIE CASTING / DAC Series

Features

40

35 700°C 30

25

20

8

0

1

2 4 Keeping Time (h)

8

YXR33

Quenched & tempered hardness 62 Quenching Temperature 1,160°C

YXR33 For High quality Insert Pin

60

YXR33 is a HSS with higher toughness which solved breakage problem often existed in SKH51. Fitted for insert pin or other inserts exposed to critical wear due to erosion.

58 1,140°C

Hardness (HRC)

56

DIE STEELS FOR DIE CASTING / DAC Series

Features *Highest strength at elevated temperature among HSS and Alloy Tool Steel. *Toughness is more than 5 times as big as SKH51. *Excellent nitridability.

1,120°C 54 1,080°C 52

50

Applications 48

*Erosion resistant insert pin. *Insert die parts.

46

Standard Heat Treatment Quench 1080-1140°C oil cool Temper 550°C-600°C Hardness 52-58 HRC

0

500

550

600

650

Tempering Temp. (°C) X 1h

Specimen after Meltdown Damage Test Microstructure as quenched & tempered (X 400)

Weight loss 46.8%

1140°C

DAC (48HRC)

14.8% DAC (48HRC) Nitriding

0.8% YXR33 (52HRC) Nitriding

Meltdown Damage Test (Specimen and Testing Condition) 90rpm Test 2h Heater

Molten Al-Alloy 700: 90mm

10mm 10mm

Specimen

9

FDAC/HPM7 Mechanical Properties (Reference)

Prehardened free machining die steel

Hardness

0.2% Yielding Tensile

(HRC)

FDAC FDAC is based on DAC for main components with addition of Sulphur for machinability. As delivered prehardened to 38-42HRC, direct cavity making is possible.

Elongation

Reduction

Strength

Strength

of Area

(MPa)

(MPa)

(%)

(%)

DAC

40

1070

1250

12

58

FDAC

40

1060

1240

11

20

HPM7

32

860

980

20

55

DIE STEELS FOR DIE CASTING / DAC Series

HPM7 HPM is prehardened to 29-33HRC and has good machinability.

Charpy I - Value (Reference) (HRC)

Longitudinal direction (J/cm2)

Transverse direction (J/cm2)

DAC

40

58

39

FDAC

40

19

10

HPM7

32

67

61

Hardness

Features *Good machinability. *As delivered prehardened, no futher heat treatment is necessary. →Possible to reduce manufacturing time and total cost.

Size of Raw Material: 280 X 640 Position of Specimen: w/2 X t/4

Applications Die for small lot , simple die, plain die, holding lock. FDAC• • • priority strength. HPM7• • • priority & toughness machinability.

Machinability

Drilling

FDAC (39HRC) DAC (38HRC) Face milling

0

1

2

3

4

5

6

7

8

Index of tool life (DAC (38HRC)=1)

Cutting condition Face milling

Drilling

Cutter

f63

Tool

HSS Co φ4

Insert

Coated cemented carbide

Cutting speed

20m/min

Number of inserts

1

Feed

0.1mm/rev

Cutting speed

130m/min

Depth

40mm (Blind)

Feed

0.15mm/Tooth

Coolant

Water-Soluble

Depth

0.5mm

Life

Number of cutting hole

Coolant

dry

Life

VB=0.3mm

10

Machinability

Comparison of machinability by Endmill machining

Machinability order DAC>DAC10>DAC55>DAC45

80 60 40 20

Annealed 0

DAC

DAC10

48HRC

DAC55

DAC45

Comparison of machinability by Facemill machining

Face mill One insert as for test purpose Insert: Cemented Carbide+Coating (TiN) Depth of cut

6000 Cutted Volume to life (cc)

DIE STEELS FOR DIE CASTING / DAC Series

Ratio of Machirability (%)

100

5000 4000 3000 2000 1000

DAC

0

80

DAC55

120

160 Cutting Speed (m/min)

200

Cutting condition by Endmill (Reference) DAC10

DAC Tool Material

Powder HSS

Annealed condition

43HRC

V=25

V=20

f=0.07

f=0.05

48HRC n. a.

Annealed condition V=15 f=0.07

48HRC n. a.

DAC55 Annealed condition V=15 f=0.07 V=20

48HRC

51HRC

n. a.

n. a.

n. a.

n. a.

V=30

V=25

f=0.07

f=0.05

Cemented Carbide+Coating

V=45

V=35

V=25

V=35

V=15

V=35

V=17

V=15

Standard edge

f=0.05

f=0.03

f=0.03

f=0.05

f=0.03

f=0.05

f=0.03

f=0.03

Cemented Carbide+Coating

V=50

V=40

V=30

V=50

V=25

V=50

V=30

V=25

Hi-speed edge

f=0.08

f=0.05

f=0.05

f=0.08

f=0.05

f=0.08

f=0.05

f=0.05

Powder HSS+Coating

n. a.

11

V=20 f=0.07

n. a.

f=0.07

Repair Welding Followings show standard repair welding method in build-up welding due to design change or repair welding due to heat crack. Material involved : DAC, DAC55, DAC10, DAC45, FDAC, E-DAC. State of Die

Welding

Welding

Welding

Rod

Method

Condition

DIE STEELS FOR DIE CASTING / DAC Series

Welding

Annealed State

350~ 400°C

300~ 400°C

DAC or same steel Welding bar 1.6~4.0φ

TIG

680~ 730°C

Furnance Cooling or Ash Cooling

250: Above

After-heating

Pre-heating

100~ 150°C Anneal 2 times in case of Large block.

Current 80~200A Flux of Ar gas 8-15R/min

Hardened State

Temp. between weldlayers

Welding Process Chart

Welding

YAG

300~ 400°C

350~ 400°C

After-heating Pre-heating 100~ 150°C

below Tempering Temperature of Die Air Cooling

RT ~100°C

Remarks 1. YAG is a brand name of Hitachi Maraging Steel used for various applications including high grade welding rod. Using YAG welding rod remarkably decreases such welding defects as "bead crack" or "pin holes". 2. TIG Welding Method (Tangsten Inert Gas Welding Method) is to make arc between tangsten electrode covered by argon gas and objects to be welded, and then wire is inserted into the heat pool generated by the arc. 3. Use lower current and finer welding wire in order to get better efficiency of welding metal. In order to prevent crater cracks, avoid an overlap of the crater of backward pass on the crater of foregoing pass. To avoid an overheat of mother material, conduct an interrupted welding with short bead. 4. Keeping time of Temper and Anneal after welding should be 1h/25mm in thickness. 5. A careful attention is to be paid of crack during grinding.

12

250: Above

Actual Performance by Customers

DIE STEELS FOR DIE CASTING / DAC Series

Diecast Products Brand

Machine Capa (die size mm)

Comparision of Actural Performance by Customers Current

Effect

Application

Autoparts surface priority

800ton 120X210X300

DAC (44HRC) 37K shot 1st heat crack

DAC (48HRC) 50K shot 1st heat crack

1.35 times

OA Components (precision die)

250 ton 80X200X300

DAC15K shot 1st heat crack 30K shot repair. 80K shot scrap

DAC10 24K shot 1st heat crack. No grinding repair. 120K shot scrap

1.6 times min.

OA Components (precision die)

650 ton 90X215X380

DAC 1K shot 1st bite 30K shot scrap

DAC10 10K shot no bite

3 times min

Autoparts surface priority

2000 ton

DAC (47HRC) 60K shot heat crack

100K shot still on service

1.6times min.

Autoparts

2500 ton

DAC (43HRC) heat crack

DAC55 (48HRC) later heat crack

4 times

Autoparts (thin insert)

n.a.

DAC 20K shot breakage

DAC55 40K shot and more

2 times

Wheel

1800 ton

DAC/DAC4 heat crack

2 times shot of DAC/DAC4 before crack

2 times

P/Computer Case (Mg)

n.a.

DAC 5K shot heat crack

DAC55 25K shot no repair

5 times min

High melting point Al-alloy autoparts

320 ton 90X200X300

DAC 5K shot 1st heat crack

DAC45 10K shot 1st heat crack but still in 2 times service

High melting point Al-alloy autoparts

Insert

DAC (52HRC) 3.5K shot meltdown

DAC45 (52HRC) 13K shot meltdown

4 times

Autoparts

Insert Pin

DAC 3K shot meltdown & galling

YXR33 10K shot still on service

3 times

High melting point Al-alloy autoparts

Insert Pin

SKH51 (60HRC) 2K shot breakage

YXR33 (54HRC)+TiN 20K shot meltdown

10 times

13

Hitachi Metals, Ltd. Head Office

http://www.hitachi-metals.co.jp/

SEAVANS North Building, 1-2-1, Shibaura, Minato-ku, Tokyo 105-8614, Japan Specialty Steel Company

Tel. +81-3-5765-4410 Fax. +81-3-5765-8317

Hitachi Metals America, Ltd. Head Office

2 Manhattanville Road, Suite 301, Purchase, NY 10577, U.S.A.

Other Office

Chicago, Detroit, Charlotte, San Jose

Tel. +1-914-694-9200 Fax. +1-914-694-9279

Hitachi Metals Europe GmbH Head Office

Immermannstrasse 14-16,40210 Duesseldorf, Germany

Tel. +49-211-16009-0 Fax. +49-211-16009-29

Hitachi Metals Singapore Pte. Ltd. 12 Gul Avenue, Singapore 629656

Tel. +65-6861-7711 Fax. +65-6861-1519

Hitachi Metals (Shanghai) Ltd. 11F, Tian An Center, No.338 NanJing Road (West), Shanghai, 200003, China

Tel. +86-21-6358-6368 Fax. +86-21-6358-6327

Hitachi Metals(Dong Guan)Specialty Steel Co.,Ltd. Guangzhou Liaison Office

Cha Shan Town, Dong Guan City, 522380 China

Tel. +86-769-640-6726 Fax. +86-769-640-6716

Dalian Branch

3-2, Koushin Mould Industrial Park III B-1-1-1F. T. Z. Dalian, China

Tel. +86-411-8718-1011/1022 Fax. +86-411-8718-1033

Tianjin Branch No.13 Workshop, Wenxin Industrial Park, Jingxiang

Road, Xiaodian Town, Beichen Economic Development Zone, Tianjin, China

Tel. +86-22-8699-3101/3102 Fax. +86-22-8699-3103

Hitachi Metals, Ltd. Beijing Liaison Office

Room No.1418, Beijing Fortune Building,5 Dong San Tel. +86-10-6590-8775 Huan Bei-Lu, Chaoyang District, Beijing, 100004 China Fax. +86-10-6590-8776

Guangzhou Liaison Office

R3303, Metro plaza,183 Tianhebei Road Tianhe District, Guangzhou city, Guangdong, 510075 China

Tel. +86-20-8755-3649 Fax. +81-20-8755-3650

•The characteristics listed in this catalog are representative average values which may differ from actual product characteristics.

•This catalog and its contents are subject to change without notice. •Do not duplicate this catalog without Metals,Ltd.

permission from Hitachi

•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 November 2007. If you cannot put a call through, please contact our Corporate Communication Group. in Tokyo below. Tel:+81-3-5765-4076 Fax:+81-3-5765-8312 E-mail : [email protected]

January 2008 (PDF)