cast materials for automotive stamping dies

Darryl YoungDarryl YoungTechnical SpecialistTechnical Specialist

Advanced Die Materials and Die ManufactureAdvanced Die Materials and Die Manufacture

Ford Motor Company Dearborn USA

Cast Materials for Cast Materials for Automotive Stamping DiesAutomotive Stamping Dies

International Sourcing Issues

International SourcingDrivers

Pressure to Reduce Investment

Pressure to Reduce Lead Time

Purchasing Agent

“ I can get it cheaper and quicker by sourcing overseas”

“Die construction source quoted to our die standards”

Result

Plant Receives Strange Die

Purchasing Agents gets Promoted

Why Is it a Problem?

MaintenancePreventative Maintenance History?

Repair Welding Rod and Procedure?

Engineering ChangesMachining: Feeds, Speeds, Cutters?

Root CausesFoundries

Foundries reluctant to pour unfamiliar grades

Don’t want liability of a cracked casting

Root CausesIndustry Standards

US(NAMMS)Mechanical Properties, Microstructure, Chemistry and As-Cast Heat Treatment

Europe (EN)Mechanical Properties-IronChemical Composition-Steel

Japan (JIS)Mechanical Properties-IronNo Tooling Grade Cast Steel Specified

Root CausesIndustry Standards

EN 1563 Standard for Spheroidal Graphite Cast Irons states; “The Material shall be designated either by symbol or by numbering as given in Table 1, Table 2, Table 3 and Table 4”

EN-GJS-350-22 = EN-JS1010

Root CausesTooling Sources

Don’t want to work with unfamiliar grades

Substitute locally available materials

Claim the substitutions are equivalent

Root CausesToolmakers Don’t Change

GG25

Everybody makes itEverybody uses itNobody Specifies it

New Symbol is EN-GJL-250

Categories of Automotive Cast Die Materials

Gray Cast Iron

Nodular(Spheroidal/Ductile) Cast Iron

Cast Steel

Gray Cast Irons

Structural Materials Match up Well

G2500 (US) EN-GJL-250(Formally GG25) (Europe)FC300 (Japan)

Low StrengthLow Surface Hardening Response

Gray Cast Irons

G3500 (US)

Better Strength

Excellent Surface Hardening Response

No Direct Equivalents in Europe or Japan

Gray Cast Irons

G3500 (US)

Discuss with Foundry

310 MPa Tensile Strength/50 mm Cast-On Sample

Alloy with Chromium and Molybdenum

Nodular Cast Iron

Structural Materials Match up Well

D4512 (US) EN-GJS-450-10 (Europe)FCD450 (Japan)

Good Resistance to CrackingMedium StrengthLow Surface Hardening Response

Nodular Cast Iron

GGG70 is now EN-GJS-700-2U (Europe)

EN-GJS-700-2U similar to FCD 700-2 (Japan)

No US(NAMMS) Equivalent

Nodular Cast Iron

GGG70L

Buyer BewareNot an EN StandardL implies Ni, Cu, Mo

Surface Hardening Response

Nodular Cast Iron D6510 (US) Vs Japan/Europe 700 Grades

Lower Tensile Strength

Much Better Ductility

Chemical Composition and Microstructure Requirements

Cast Steels

US S0050A, Carmo, Cast Cut #1

Europe1.7140, 1.2320, 1.2333

JapanICD-5, SKD12

Cast SteelsCarmo(US) Vs 1.2333(Europe)

Match on Chemistry

PurchaserTramp ElementsHeat TreatmentMechanical Properties

Cast SteelsCast Cut #1(US) Vs 1.7140 a.k.a Fermo (Europe)

Very Close on Chemistry

Unauthorized/Unlicensed Foundries

Heat Treat/Mechanical Properties?Intellectual Property Issues?

Cast SteelsS0050A (US) Vs 1.7140, 1.2320 (Europe)

Easier to WeldSafer to CastLess Surface Hardening ResponseLess Wear Resistance

Cast SteelsJapan

Long Lead TimesTwo Popular Grades

ICD-5

SKD12

Cast SteelsICD-5

Proprietary name treated like Industry Standard

Originally a product of Hitachi Steel Co.

Reasonable Substitutes1.7140 (Fermo)Cast Cut #1

Cast SteelsSKD12

SKD12 SpecificationWrought MaterialBuyer Beware

Similar to 1.2363(Europe) & A2(US)

Cast SteelsSKD12

Considered Surface Hardenable?

ChallengingSurface HardeningCastingWeldingMachining

Cast SteelsNew Grades

Caldie-Uddeholm

GP4M-Dorrenberg

Currently Only Available in Europe

High Potential for AHSS Applications

Cast SteelsCaldie/GP4M

High Temper Resistance

Excellent Coating Substrate

Current Limitation

Physical Vapor Deposition (PVD) Chamber Size

Cast SteelsCaldie/GP4M

Reduced Cost Vs is 1.2379 Bar Stock Inserts

Less Machining

Less Chance of Breakage

Easier Welding

Equivalent Wear Resistance when Coated

Cast Materials for Cast Materials for Automotive Stamping DiesAutomotive Stamping Dies

International Sourcing Issues

Questions?