Doosan Heavy Industries & Construction
DOOSAN PLASTIC MOLD STEEL
GLOBAL LEADER IN POWER & WATER
Doosan has continued to research and develop technology for producing outstandingmold steel, which is now being supplied for the benefit of customers worldwide.Plastic mold steel from Doosan is also accelerating the development of industry.
DOOSAN HEAVY INDUSTRIES & CONSTRUCTION
DOOSAN PLASTIC MOLD STEEL
CONTENTS
INTRODUCTION ‥‥‥‥‥‥‥‥‥‥‥‥ 04
PLASTIC MOLD STEELSHP1A / HP4A(D1) / HP4MA(D2) ‥‥‥‥‥ 06
HIGH QUALITY PLASTIC MOLD STEELSHP70 / HEMS1A ‥‥‥‥‥‥‥‥‥‥‥‥ 10
PHYSICAL PROPERTIES ‥‥‥‥‥‥‥‥‥ 13
MANUFACTURING PROCESS ‥‥‥‥‥‥‥ 14
03
DOOSAN PLASTIC MOLD STEEL
INTRODUCTION
Mirror polishability
General Products Semi-transparentProducts
transparentProducts
Super mirrorfinish ProductsH
ardn
ess HP1A
HP4A(D1)
HP4MA(D2)
HP70
HEMS1A
Polishing Property(Schematic Diagram)
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DOOSAN HEAVY INDUSTRIES & CONSTRUCTION
0�
Doosan’s Plastic Mold Steel “HP”
DOOSAN Heavy Industries & Construction Co., Ltd. (DOOSAN) has been producing various types of casting& forging products for the many years ranging from power generator, chemical vessel, steel mill, shipbuilding to cement industries.
Since being founded, DOOSAN has also supplied plastic mold steels and tool steels to the high technologysectors such as electric, electromagnetic, optical, telecommunication industries as well as the fields ofsemiconductors, precision machinery, construction machinery, automobile, etc.
DOOSAN is very pleased to be given the chance to supply its products to the world. As mentioned above,its products are well known for their excellence in quality. Doosan is proud to inform you that it has patentsfor plastic mold steels in Korea as well as acquired certificate of ISO 9001 (ANSI / ASQC Q91).
DOOSAN will continuously do its very best in improving the quality of plastic mold steels to its limit. Wewill promise satisfaction to all of our customers.New types of high-quality free-cutting steel for plastic moldings, HP series plastic mold steels, have beendeveloped under a strict quality assurance system with DOOSAN’s modern facilities.
Compared with the conventional steel materials of other companies, the machining time for our newproducts can be reduced by a maximum of 40%. Because of special alloy elements in our HP series plasticmold steels, one can obtain better etching workability, polishing workability and weldability than in manyother products.
As a result, not only is the efficiency of metal mold work improved and the service life of the cutting toolsgreatly extended, but one can also make excellent plastic products. HP steels and HEMS1A are highperformance and high-precision plastic mold steel.
Use of our newly developed HP steels and HEMS1A can make a major contribution to the improvementproductivity and rationalization of production.
DOOSAN’s Plastic Mold Steels
DOOSANBRAND D/N
REFERENCE SPECIFICATION SUPPLIEDCONDITION
APPLICATIONSDIN AISI JIS ASSAB
HP1A1.1210
Improved10�0
ImprovedS��C
Improved- Prehardened
· General purpose large size mold base
HP4A(D1)1.2311
Improved4140
ImprovedSCM44oImproved
618Improved
Prehardened · Core & Cavity · General purpose mold for Mass-production
HP4MA(D2)1.2738
ImprovedP20
ImprovedSNCM
Improved718
ImprovedPrehardened
· Higher hardness mold · Bumper mold · General purpose mold for Mass-production
HP70 -P21
ImprovedDaido’sNAK80
- Prehardened · High grade mold base for mirror surface & EDM requirement
HEMS1A1.2083
Improved420
ImprovedSUS420J2Improved
STAVAXImproved
Annealed
· Corrosion resistant precision plastic mold · Glass mold & TV braun tube mold
HP1A / HP4A(D1) / HP4MA(D2)
Material HP1A HP4A(D1) HP4MA(D2)
C >0.�0 0.2� ~ 0.3� 0.2� ~ 0.3�
Ni <0.�0 0.20~0.�0 0.20~0.�0
Cr - 1.00 ~ 1.�0 1.�0 ~ 2.00
Mo - 0.20~0.40 0.30~0.60
SpecialAlloy
Added Added
Material Characteristics
HP1A
· General Purpose for Plastic Molding · Outstanding Machinability · Less Residual Stress and Distortion
HP4A(D1)
· Excellent Machinability · Superior Cleanliness, Weldability and Photo-etching · Better Hardness Distribution
HP4MA(D2)
· Better Machinability · Outstanding Hardness Distribution and Wear Resistance · Superior Cleanliness and Photoetching
Manufacturing Characteristics
MELTING
· Superior Cleanliness due to High Vacuum Degassing Process
FORGING
· No Solidification Defect by Using 130MN & 42MN Press
HEAT TREATMENT
· Excellent Mechanical Properties by Optimal Heat Treatment
Main Concepts of Developing HP4A(D1) & HP4MA(D2)
· Adopting new concept in alloy design to make up for weak points with maintaining strong points · Optimizing quality heat treatments to get mechanical properties.
Quality Properties
█ Chemical Compositions(Unit :wt%)
Material HP1A HP4A(D1) HP4MA(D2)
SurfaceHardness
HS 28~33 HRc 28~32 HRc 31~34
YieldStrength(N/㎟)
3�0 ~ 4�0 6�0 ~ 800 7�0 ~ 900
TensileStrength(N/㎟)
700 ~ 800 800 ~ 900 900 ~ 1100
█ Mechanical Properties
DOOSAN PLASTIC MOLD STEEL
DOOSAN HEAVY INDUSTRIES & CONSTRUCTION
07
Har
dnes
s(H
Rc) 36
34
32
30
28
26
24
22
20
-200 -100 0 100 200
HP4MA (D2)HP4A (D1)
Distance from center(mm)
Stre
ngth
(n /
)
HP1A HP4A (D1) HP4MA (D2)
700
600
500
400
300
200
1000
900
800
100
cross sectional Hardness distributionHardness is uniformly distributed throughoutthe cross sectionYield tensile
photo etching
there is no serious trouble in the most segregated part of 770mm heavy block.
segregation
HP4A (D1) and HP4MA (D2) are superior to HP1Ain segregation.
Hp4a(d1) Hp4Ma(d2)
Hp1a Hp4Ma(d2)
Mechanical properties graph
Plastic Mold Steel-121029-2_Plastic Mold Steel-0511 12. 10. 29. 오오 3:51 Page 7
DOOSAN HEAVY INDUSTRIES & CONSTRUCTION
07
█ Photo etchingThere is no serious trouble in the most segregated part of 770mm heavy block.
HP4A(D1) HP4MA(D2)
█ SegregationHP4A (D1) and HP4MA (D2) are superior to HP1Ain segregation.
HP1A HP4MA(D2)
█ Mechanical Properties Graph █ Cross Sectional Hardness DistributionHardness is uniformly distributed throughoutthe cross section
DOOSAN PLASTIC MOLD STEEL
HP1A / HP4A(D1) / HP4MA(D2)
TEST CONDITION
• Cutter : M41�SP-0�R-12• Insert : SPKN1203EDTR-HP/ TT7070
█ Machinability
HP4A(D1) & HP4MA(D2) give 2 timeslonger in life of tool and shorter inmachining time than DIn materials.
• V=2�0m/min f=0.1�mm/tooth• d=2.0mm Center cutting dry
Hp1a
repair welding Manualdescription
Hp4a(d1) Hp4Ma(d2)remarks
AWSER70S-4ER70S-6
AWSER80S-B2ER80S-G
AWSER80S-B2ER80S-G
ER9oS-B3
Welding Rod : 1.6ø, 2.4ø
Fuel : LnGFuel Pressure : 0.5 kg/cm2
tP (Holding temperature)HP1A : 270 20HP4A(D1) : 350 20HP4MA(D2) : 320 20
Required Polishing and Etching Workability
250 50(200~300)
WeldingPost Heating
(250~350 )Preheating
WeldingSlow cooling( 50 /hr)
300
PWHt
(500~600 )
(200~350 )Preheating
Filler Metals
Preheat temp.
Post Heat treatment
Post-Weld Heattreatment (PWHt)
*Slow cooled using insulating materials.
300 50(250~350)
250 50(200~300)
30(min) / inch
1-2hr
*
*
procedures for repair welding
In case of design change and defects during operation, repair welding has to be performed. Due to high strength of mold steel repair welding requires the extreme care and strict supervision.
max.100 /hr
tP
VBm
ax (m
m)
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.021 3 40
1.2311
Hp4a(d1)
Cutting Distance (mm) Cutting Distance (mm)
life of tool
VBm
ax (m
m) 0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
21 3 40
1.2738
1.6 3.3 1.5 3.2
Hp4Ma(d2)
life of tool
Machinability
HP1A / HP4A(D1) / HP4MA(D2)
DOOSAN PLASTIC MOLD STEEL
HP4A(D1) & HP4MA(D2) give 2 timeslonger in life of tool and shorter inmachining time than DIn materials.
• Cutter : M415SP-05R-12
• Insert : SPKn1203EDtR-HP/ tt7070
• V=250m/min f=0.15mm/tooth
• d=2.0mm Center cutting dry
test condition
Plastic Mold Steel-121029-2_Plastic Mold Steel-0511 12. 10. 29. 오오 3:51 Page 8
cutting Distance(m) cutting Distance(m)
9
DOOSAN HEAVY INDUSTRIES & CONSTRUCTION
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DOOSAN HEAVY INDUSTRIES & CONSTRUCTION
09
weldability
Improved consistency in hardness before/after PWHt.
Distance from the center (mm)
Har
dnes
s (H
v) 500
450
400
350
300
250
200
150500
450
400
350
300
250
200
150
42 6 8 100
as weld
Hp4a(d1). surface
after PWHt
as weld
Hp4a(d1). center
after PWHt
Vick
ers
Har
dnes
s (L
oad:
5kg) 650
600
550
500
450
400
350
300
250
200
150
-25 -20 -15 -10 -5 0 5 10 15 20 25
Hp4Ma
Hp4Ma(d2)
base HaZ weld HaZ base
weld HaZ base
as weldafter PWHt
after PWHtas weld
Plastic Mold Steel-121029-2_Plastic Mold Steel-0511 12. 10. 29. 오오 3:51 Page 9
█ WELDABILITY
Improved consistency in hardness before/after PWHT.
DOOSAN PLASTIC MOLD STEEL
HP70 / HEMS1A
MaterialChemical Composition(wt, %)
C Ni Cr Mo Special Alloys
HP70 < 0.2� > 2.00 - < 0.�0 Added
HEMS1A 0.2�~ 0.30 ≤ 0.30 12.00 ~ 12.�0 ≤0.�0 Added
Characteristics
HP70
· Maintain excellent surface finish · Uniform hardness throughout the cross section · Extreme hardness and superior wear resistance · Excellent electric discharge machinability
HEMS1A
· Excellent corrosion resistance · Excellent mirror finishing · High precision · Uniform hardness throughout the cross section
█ Chemical Compositions
Quality Properties
█ Vacuum-Degassing Process
Our free cutting steels are vacuum-degassed and forged.They have 1) excellent cleanliness 2) no pin holes 3) desegregation of alloy elements.
Material Yield Strength(kgf/㎟)
Tensile Strength(kgf/㎟)
Elongation(%)
Reduction of Area(%)
Surface Hardness(HRc)
HP70 100 ~ 11� 120 ~ 13� > 17 > �2 37 ~ 41
HEMS1A 60 ~ 70 7� ~ 8� > 2� > �0 23 ~ �2
█ Mechanical Properties
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DOOSAN HEAVY INDUSTRIES & CONSTRUCTION
Har
dnes
s(H
Rc)
Har
dnes
s(H
Rc)
Distance from center (mm)
50
45
35
40
30
26
250 200 150 100 50 0 50 100 150 200 250
Hp70
Cutt
ing
Forc
e(n
)
Cutting Depth (mm)
• table Moving Speed: 160mm/min.• Face Milling ConditionCutting Speed: 261m/min.Insert type: SPKn1504EDRLubricant: no
Hp70 Hp70
4700c, 5hr
Hp70
520 0c, 5hr
Hp70
Har
dnes
s(H
v)
Har
dnes
s(H
v)
Distance from the surface (10-2mm) Distance from the surface (10-2mm)
Heat AffectedLayer
• EDM Condition: M/C: tron150c: Electrode: Copper(8ø ): Surface roughness: Ra4
800120
100
80
60
40
20
800 500
450
400
350
300
250
200
0 2 4 6 8 10 12 14 16 18 20
700
600
500
400
300
0 5 10 15 20 25 30 35 40
00 100 200 300 400
700
600
500
400
300
200
1.0 1.5 2.0
tens
ile S
tren
gth
(kgf
/mm
2 )
temperature (0C)
Machinability High temperature tensile properties
nitriding characteristics electric discharge Machining
cross-sectional Hardness distribution
HeMs1a
0
71
60
50
39
30
50 100 50 0Distance from the surface (mm)
(after Q+t)
DOOSAN HEAVY INDUSTRIES & CONSTRUCTION
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Plastic Mold Steel-121029-2_Plastic Mold Steel-0511 12. 10. 29. 오오 3:51 Page 11
DOOSAN PLASTIC MOLD STEEL
Har
dnes
s(H
Rc) 65
60
55
50
45
40
35
30
25
100asquenched 200 300 400 500 600
HeMs1aQuenching temp. : 1025 0C
tempering temperature (0C)
tempering Hardness curve
polishing workability
Material remark
Hp70
HeMs1a
0.019
ra.( ) rmax.( )
0.01
0.167
0.031 Diamond paste use
Clea
nlin
ess
(%)
0.14
0.12
0.10
0.08
0.06
0.04
0.02
0
Wei
ght L
oss
(g/
g) 0.20
0.15
0.10
0.05
0.00
5% hydrochloric acid
HEMS1A steel, being treated with vacuum-degassingand ESR process, shows an excellent cleanliness.
MaterialQuenching (0C)
1000 ~1050 oil cooling
100 ~ 500 45 ~ 52
23 ~ 33550 ~ 700
tempering (0C)
Heat treatment conditions
HeMs1a
surface Hardness
(HRc)
HP70 / HEMS1A
DOOSAN PLASTIC MOLD STEEL
Heat treatment
AISI 420 HEMS1A
cleanliness
AISI 420 HEMS1A
corrosion resistance
Fig. shows workability of polishing and finishing.
Plastic Mold Steel-121029-2_Plastic Mold Steel-0511 12. 10. 29. 오오 3:51 Page 12
HP70 / HEMS1A
13
DOOSAN HEAVY INDUSTRIES & CONSTRUCTION
Material Temperature(℃)
Thermalconductivity
(W / m·K)
Specific heat(Cal / g·℃)
Coefficient ofthermal expansion
(10-6 /℃)
HP1A
Room temperature
100200300400�00600
-�0.24248.14844.79941.031
--
-0.1160.12�0.1320.138
--
-13.7614.�11�.361�.8116.2216.�4
HP4A(D1)
Room temperature
100200300400�00600
-42.28741.86840.19337.263
--
-0.11�0.1240.1310.137
--
-13.8714.3214.821�.�81�.7�16.08
HP4MA(D2)
Room temperature
100200300400�00600
-40.61240.19339.3�637.681
--
-0.1170.1260.13�0.139
--
- 11.8213.2314.1614.6414.891�.14
HP70
Room temperature
100200300400�00600
33.117633.�78132.992031.191728.80�226.083822.1482
0.4990.�130.�440.�970.6440.7280.766
-12.8912.4413.3814.0114.1714.�6
HEMS 1A
100200300400
2�.12126.37727.21428.0�2
-
11.611.912.412.7
█ Physical Properties
PHYSICAL PROPERTIES
DOOSAN PLASTIC MOLD STEEL
MANUFACTURING PROCESS
Manufacturing Process
1. Melting > 2. V.S.D(Ingot Making byVacuum Steam Degassing) > 3. E.S.R >
4. Heating > �. Forging > 6. Heat treatment > 7. Inspection
Preliminary HeatTreatment
Machining
Quality Heat TreatmentInspectionShipment
Forging
Melting
VacuumDegassing
Refining Ingot Making inVacuum Condition
Ingot Making
Heating
E.S.R
Doosan Heavy Industries & Construction SEOUL OFFICE 46� Gangnam-daero, Seocho-Gu, Seoul 137-920 KoreaTel. 82-2-�13-6114 Fax. 82-2-�13-6200
www.doosanheavy.comHEAD OFFICE AND CHANGWON PLANT22 DoosanVolvo-ro, Seongsan-GuChangwon, Gyeongnam 642-792 KoreaTel. 82-��-278-6114, 7114 Fax. 82-��-264-���1,���2