mike koebel western moldmakers trade fair - … bohler.pdf · mike koebel western moldmakers trade...
TRANSCRIPT
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Mike Koebel Western Moldmakers Trade Fair November 11, 2015
Tooling Materials for Plastic Molding Applications
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Factors that Determine Mold Steel Requirements
Aggressive Resins:
• corrosive by-products
• abrasive fillers
Design Requirements:
• complexity of parts
• process
Lens Quality/Cosmetic Appearance:
• polishability
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Stainless Mold Steels
Grade DescriptionWorking
Hardness (HRC)
Stavax ESR 420 modified stainless steel 46 – 52
Mirrax ESR 400 series stainless for medium to large molds 46 - 51
Mirrax 40 400 series stainless delivered in the pre-hardened condition 40
CorraxPrecipitation hardening stainless with outstanding corrosion resistance
46 - 50
ElmaxPM stainless steel with an excellent combination of corrosion and wear resistance
56 – 60
Royalloy Pre-hardened, free-machining stainless holder material 31 – 36
(290-330 BHN)
BeCu Alloy 172Pre-hardened, beryllium copper alloy for high thermal conductivity
30 HRC or 40 HRC
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The size of the sphere corresponds
to the relative corrosion resistance
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C Si Mn Cr V S
AISI 420 0.15 min 1.00 max 1.00 max 12.0 – 14.0 0.030 max
Stavax ESR 0.38 0.90 0.50 13.6 0.30 0.003
• Small-to-medium size cavites and cores where high polishability is required and/or when corrosive plastics are molded
• Compression molds
• Dies and calipers for plastic extrusion
• Structural components
• Long running molds
Stavax ESR – 420 modified
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Mold Polishing & Finishing
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Polishing Sequence
240 SiC
6µ Diamond Paste
1µ Diamond Paste
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Sulfide “Stringers”
• Polishability
• Corrosion
• Toughness
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1
2
3
Relatively Hard Inclusion
Steel Matrix
Void
Non-Metallic Inclusions
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Polishability
ESR vs. Standard
Perfect polished finish
Poor polished finish caused by impurities in steel
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Ingot Casting
The long solidification time results in the formation of large, blocky carbides that will later align themselves with the rolling/forging direction.
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Electroslag Remelting (ESR)
ADVANTAGES OVER CONVENTIONAL STEELS• An improved solidification microstructure
• More homogeneous material
• Cleaner material
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Stavax Heat Treatment
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Continuous Cooling Transformation (CCT) Curve
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Grain Boundary Carbides
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Stress Corrosion Cracking (SCC)
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Ensure that the cooling water chemistry does not encourage SCC
• Maintain chlorides below 10 ppm and pH-level between 5-8
Eliminate dead zone in the cooling circuits
• Design to create and maintain turbulent flow conditions throughout the entire cooling circuit
• Ream out cooling lines when possible• Minimize sharp cooling line junctions especially in combination with thin walls
Choose plugs, baffles and other mold hardware to minimize galvanic corrosion effects
• Choose 300/400 series stainless, plastic/Teflon, etc. versus brass for moldhardware
• Avoid pipe taps, use straight taps with O-ring plugs or use expansion plugs as an alternative
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Pressure/Protective Gas Electoslag Remelting (PESR)
EQUIPMENT DATA:� Remelting under pressure
and/or protective atmosphere � Ability to alloy steel with nitrogen� Low level of alloy segregation� Extremely low sulfur content� Minimum levels of other
nonmetallic inclusions
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C Si Mn Cr Ni Mo V Nitrogen
Mirrax ESR 0.25 0.35 0.55 13.3 1.35 0.35 0.35 +
Uddeholm Mirrax ESR
• Better corrosion resistance and better ductility than a 420 ESR mold steel.
• Pressurized Electro-Slag Remelted (PESR) yields a clean, homogeneous material, ideal for lens quality tooling.
• Typically quenched & tempered to a hardness level of 49 – 51 HRC.
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Mirrax ESR• Produced via Pressurized-ESR
• Sound microstructure at the mold center (area where cavity is machined and/or cooling lines are located)
• Higher toughness levels• Improved corrosion resistance
• Improved resistance to pitting and SCC
• Increased hardenability – important for thicker cross sections
• High temperature temper • Lower residual stresses
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Mirrax – Note Heat Treatment Considerations
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Corrosion Resistance
• Mirrax ESR has better corrosion resistance compared to current Type 420 stainless steel
• Salt spray test (5% NaCl solution, pH 3 at 68°F)
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Mirrax ESR
Type 420 Stainless
centresurface
Specimens taken from heat treated blocks with dimension:10 x 19.7 x 24” (254 x 500 x 610 mm)1870°F + 930°F (1020°C + 500°C) / 2x2h
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Impact Testing
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Impact Toughness
0123456789
10
Low temp, 50 HRC High temp, 51 HRC
Mirrax ESR420 ESR
Mirrax ESR vs. 420 ESR, 10 x 24”
CV
N Im
pac
t To
ug
hn
ess
(Jo
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, ST
@ c
ore
)
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C Si Mn Cr Ni Mo V Nitrogen
Mirrax 40 0.21 0.9 0.45 13.5 0.6 0.2 0.25 +
Uddeholm Mirrax 40
• Prehardened stainless steel ~40 HRC (360 – 400 BHN)• No heat treament is required (simplifies tool building process
& reduces cost)• Pressurized Electro-Slag Remelted (PESR) yields a clean,
homogeneous material, ideal for polishing• Excellent machinability and high-level of ductility & toughness
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C Si Mn Cr Ni Mo AlCorrax 0.03 0.3 0.3 12.0 9.2 1.4 1.6
Corrax
• Precipitation hardnening stainless • As-supplied ~34 HRC (solutionized condition)• Working hardness range 34 – 49 HRC (age-hardened) • Polishability is comparable to P20; not recommended
for optical finishes.
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1) Not suitable for Optical or SPI #1 Finish applications (expect similar polishabilty to our P20)
2) Material will shrink during the aging (hardening) process3) Reduced cutting speeds (Vc) relative to a Type 420 stainless
Three important points to bring to the attention of the customer:
Corrax
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PM Facility – Kapfenberg, Austria
Established 1999Production capacity:
> 6000 metric tons
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MICROCLEAN PM Process
"3rd Generation"
Powder Technology
Gas Atomization / Powder Collection
Capsule Filling
Special Melting / Refining Practice
Capsule Welding
Hot Isostatic Pressing (HIP)to 100% Density
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MICROCLEAN PM Powder Production
Rapidly Solidified Powder
Gas Atomization (N2) Spherical Shape / Uniform Composition
100µµµµ
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fabricated steel canister loaded with powder
Consolidation to 100% Densityby Hot Isostatic Pressing (HIP)
Standard Capsule Dimension
17.7- 21.7ӯ (450-550 mm)
x 67” (1700 mm); 2 to 3 mtons
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Consolidation to 100% Densityby Hot Isostatic Pressing (HIP)
Capsule is heated to 2100°F (1150°C)
Compaction @1000 bars(~14,500 psi)
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Comparison of Microstructures
Conventionally Cast P/M Production Route
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Uddeholm Elmax
• Typical working hardness 56-60 HRC • Abrasive wear applications where corrosion resistance is required • Injection molding components such as screws and barrel liners• Molds for the electronics industry (IC, connectors, switches)• High wear inserts (nozzles, gate areas)
C Si Mn Cr Mo VElmax SuperClean 1.7 0.4 0.3 18.0 1.0 3.0
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Non-Stainless Grades for Mold Applications
Grade DescriptionWorking
Hardness (HRC)
Orvar Superior Premium H13, excellent toughness and polishability 44 – 52
Dievar Outstanding toughness (greater than H13) 44 - 52
W400 VMR Optimal toughness level 44 – 52
W360 Isobloc Additional wear resistance and compressive strength 52 - 58
S7 MQ High toughness, shock resistant 52 - 56
Caldie Outstanding toughness & high polishability 54 – 61
Vanadis 4 ExtraPM – 4% Vanadium, excellent combination of wear resistance and toughness
58 - 62
K294 Microclean PM – 10% Vanadium, extreme abrasive wear applications 58 - 64
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Orvar SuperiorPremium H13
• Good wear properties and resistance to indentation• Outstanding polishability and texturing characteristics• Excellent toughness• Electro-slag remelted (ESR)
C Si Mn Cr Mo V
Orvar Superior 0.39 1.0 0.4 5.2 1.4 0.9
As-delivered: 180 Brinell
Typical Application Hardness 44 – 52 HRC
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Mold Quality S7
• Good toughness and wear resistance• Injection, compression and transfer molds• Mold components (slides, ejector pins, core pins and
stripper rings)
C Si Mn Cr Mo S
Mold Quality S7 0.53 0.30 0.7 3.2 1.5 0.005
As-delivered: 200 Brinell
Typical Application Hardness 52 – 56 HRC
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Böhler W360 Isobloc
• Typical working hardness 52 – 57 HRC • ESR quality; excellent cleanliness and toughness
C Si Mn Cr Mo VW360 Isobloc 0.50 0.20 0.25 4.5 3.0 .55
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Uddeholm Caldie Composition
• Matrix Tool Steel – Essentially free of Primary Carbides
• Produced using PESR
• Typical working hardness 56-61 HRC
C Si Mn Cr Mo VCaldie 0.7 0.2 0.5 5.0 2.3 0.5
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Tempering Curves S7 and Caldie
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Caldie Microstructure
Matrix Tool Steel
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HSS Microstructures
Conventionally Cast P/M Production Route
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Uddeholm Vanadis 4 Extra
• Typical working hardness 58-62 HRC • Excellent choice for resins containing abrasive fillers• Smaller, core/cavity inserts with complex geometries
C Si Mn Cr Mo VVanadis 4 Extra 1.4 0.4 0.4 4.7 3.5 3.7
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Böhler K294 Microclean
• Typical working hardness 58-64 HRC • Extreme, abrasive wear applications• Injection molding components such as screws, nozzles and
barrel liners
C Si Mn Cr Mo VK294 Microclean 2.5 0.9 0.5 5.2 1.3 9.7
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C Si Mn S Cr Ni Mo V
ThruhardSupreme
0.26 0.10 1.45 0.002 1.25 1.05 0.50 0.10
Thruhard Supreme High Hard
• Prehardened to 310 to 355 BHN (~33 to 38 HRC)• Polishability up to a 600 grit (high gloss finish)• Good weldability• High thermal conductivity
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BeCu Alloy 172
• High Hard: 36-42 HRC and Low Hard: 26-32 HRC• High thermal conductivity; 3-4 times that of steel• Good corrosion resistance• Anti-galling properties• Weldable
Co + Ni Be CuBeCu Alloy 172 0.25 1.9 97+
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APPLICATIONS
•Blow molds: pinch offs, neck rings, handle inserts•Injection molds: molds, cores, inserts•Injection nozzles and manifolds for hot runner systems
BeCu Alloy 172
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Filler Metal for Welding Plastic Mold Materials
Grade Diameter (mm) - Type Diameter (mm) - Type
Impax 2.5, 3.2, 4.0 - Electrode 1.0, 1.6 – GTAW/TIG
Caldie 2.5, 3.2 - Electrode 1.0, 1.6 – GTAW/TIG
*Stavax -- 1.0, 1.6 – GTAW/TIG
Mirrax -- 1.0, 1.6 – GTAW/TIG
Corrax -- 1.0, 1.6 – GTAW/TIG
Moldmax -- 1.6, 2.4, 3.2 – GTAW/TIG
*Available as 0.2, 0.3, 0.4, 0.5 and 0.6 mm diameter for laser & micro welding
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Plastics Mold Steel www.bucorp.com
1-800-638-2520