SAE STEEL NON- DEFORMING SAFETY IN DEPTH OF TOUGHNESS RESISTANCE WEAR RESIST- MACHIN-
DESIGNATION PROPERTIES HARDENING HARDENING (a) TO ANCE ABILITY
SOFTENING
EFFECT OF
HEAT
WATER
HARDENING
TOOL STEELS
[UP]
W108 POOR FAIR SHALLOW GOOD (b) POOR FAIR BEST
W109 POOR FAIR SHALLOW GOOD (b) POOR FAIR BEST
W110 POOR FAIR SHALLOW GOOD (b) POOR GOOD BEST
W112 POOR FAIR SHALLOW GOOD (b) POOR GOOD BEST
W209 POOR FAIR SHALLOW GOOD POOR FAIR BEST
W210 POOR FAIR SHALLOW GOOD POOR GOOD BEST
W310 POOR FAIR SHALLOW GOOD POOR GOOD BEST
SAE STEEL NON- DEFORMING SAFETY IN DEPTH OF TOUGHNESS RESISTANCE WEAR RESIST- MACHIN-
DESIGNATION PROPERTIES HARDENING HARDENING (a) TO ANCE ABILITY
SOFTENING
EFFECT OF
HEAT
SHOCK
RESISTING
TOOL STEELS
[UP]
S1- CHROME- FAIR GOOD MEDIUM GOOD FAIR FAIR FAIR
TUNGSTEN
S2- SILICON- W POOR (c) W POOR (c) MEDIUM BEST FAIR FAIR GOOD
MOLYBDENUM
O FAIR (c) O GOOD (c)
S5- SILICON- W POOR (c) W POOR (c) MEDIUM BEST FAIR FAIR FAIR
MANGANESE
O FAIR (c) O GOOD (c)
COLD WORK
TOOL STEELS
OIL
HARDENING
O1- LOW GOOD GOOD MEDIUM FAIR POOR GOOD GOOD
MANGANESE
02- HIGH GOOD GOOD MEDIUM FAIR POOR GOOD GOOD
MANGANESE
O6- FAIR GOOD MEDIUM FAIR POOR GOOD BEST
MOLYBDENUM
MEDIUM
ALLOY AIR
A2-5% CHROME BEST BEST DEEP FAIR FAIR GOOD FAIR
AIR HARD
SAE STEEL NON- DEFORMING SAFETY IN DEPTH OF TOUGHNESS RESISTANCE WEAR RESIST- MACHIN-
DESIGNATION PROPERTIES HARDENING HARDENING (a) TO ANCE ABILITY
HIGH CARBON-
HIGH CHROME
D2-HIGH BEST BEST DEEP FAIR FAIR BEST POOR
CARBON- HIGH
D3-HIGH GOOD GOOD DEEP POOR FAIR BEST POOR
CARBON- HIGH
D5-HIGH BEST BEST DEEP FAIR FAIR BEST POOR
CARBON- HIGH
COBALT
D7- HIGH BEST BEST DEEP POOR FAIR BEST POOR
CARBON- HIGH
CHROME-
HIGH
VANADIUM
SAE STEEL NON- DEFORMING SAFETY IN DEPTH OF TOUGHNESS RESISTANCE WEAR RESIST- MACHIN-
DESIGNATION PROPERTIES HARDENING HARDENING (a) TO ANCE ABILITY
SOFTENING
EFFECT OF
HEAT
HOT WORK
TOOL STEELS
[UP]
CHROME BASE
TYPES [UP]
H11- CHROME- GOOD GOOD DEEP GOOD GOOD FAIR FAIR
MOLYBDENUM-
V
H12- CHROME- GOOD GOOD DEEP GOOD GOOD FAIR FAIR
MOLYBDENUM-
H13- CHROME- GOOD GOOD DEEP GOOD GOOD FAIR FAIR
MOLYBDENUM-
VV
TUNGSTEN
BASE TYPES I
[UP]
H21- TUNGSTEN GOOD GOOD DEEP GOOD GOOD FAIR FAIR
SAE STEEL NON- DEFORMING SAFETY IN DEPTH OF TOUGHNESS RESISTANCE WEAR RESIST- MACHIN-
DESIGNATION PROPERTIES HARDENING HARDENING (a) TO ANCE ABILITY
SOFTENING
EFFECT OF
HEAT
HIGH SPEED
TOOL STEELS
[UP]
TUNGSTEN
BASE TYPES II
T1- TUNGSTEN GOOD GOOD DEEP POOR GOOD GOOD FAIR
18-4-1
T2- TUNGSTEN GOOD GOOD DEEP POOR GOOD GOOD FAIR
18-4-2
T4- COBALT- GOOD FAIR DEEP POOR BEST GOOD FAIR
TUNGSTEN 18-4-
1-5
T5- COBALT- GOOD FAIR DEEP POOR BEST GOOD FAIR
TUNGSTEN 18-4-
2-8
T8- COBALT- GOOD FAIR DEEP POOR BEST GOOD FAIR
TUNGSTEN 18-4-
2-5
SAE STEEL NON- DEFORMING SAFETY IN DEPTH OF TOUGHNESS RESISTANCE WEAR RESIST- MACHIN-
DESIGNATION PROPERTIES HARDENING HARDENING (a) TO ANCE ABILITY
SOFTENING
EFFECT OF
HEAT
MOLYBDENUM
BASE TYPES
[UP]
M1- GOOD FAIR DEEP POOR GOOD GOOD FAIR
MOLYBDENUM
8-2-1
M2- GOOD FAIR DEEP POOR GOOD GOOD FAIR
MOLYBDENUM-
TUNGSTEN 6-6-2
M3- GOOD FAIR DEEP POOR GOOD BEST FAIR
MOLYBDENUM-
TUNGSTEN 6-6-3
M4- GOOD FAIR DEEP POOR GOOD BEST FAIR
MOLYBDENUM-
TUNGSTEN 6-6-4
SAE STEEL NON- DEFORMING SAFETY IN DEPTH OF TOUGHNESS RESISTANCE WEAR RESIST- MACHIN-
DESIGNATION PROPERTIES HARDENING HARDENING (a) TO ANCE ABILITY
SOFTENING
EFFECT OF
HEAT
SPECIAL
PURPOSE TOOL
STEELS [UP]
LOW ALLOY
TYPES [UP]
L6- NICKEL- FAIR GOOD MEDIUM FAIR POOR FAIR FAIR
CHROME
L7- CHROME FAIR GOOD MEDIUM FAIR POOR GOOD FAIR
(a) These are intended to emphasize major differences between the groups of steels and do not account for the minor differences in depths of hardening that exist between
steels of the same group. This is particularly true of the Water Hardening W Steels which are frequently furnished with varying degrees of hardenability as listed in Table 1.
(b) Toughness decreases somewhat with increasing depth of hardening.
(c) W as shown here indicates water quench. O as shown here indicates oil quench.
W-1 Tool Steel
Heat treat 1450-1600 F
temperature
Quench Water or Brine
Hardness Rockwell 56c
Applications Blacksmith tools
Cold Chisels
Hand punches
Cold Forming Tools
Knives
Scissors and Shears
Razors
Woodworking Chisels
Disadvantages Water hardening tool
steels tend to experience
significant distortion during
the quench operation. In
addition, the hardening
operation applies only to
the outer "case" of the
material, rather than being
"through-hardened".
O-1 Tool Steel
Heat treat 1450-1600 F
temperature
Quench Oil
Hardness Rockwell 62c-64c
Applications Taps
Reamers
Knurling Tools
Shear Blades
Drills
Coining Dies
Trimming Dies
Disadvantages Oil hardening tool steels
tend to experience less
distortion during the
quench operation, but they
do still show distortion
from the original size. The
hardening operation is
more thorough than with
water hardening steels,
but not as thorough as the
air-hardening grades.
A-2 Tool Steel
Heat treat 1700-1900 F
temperature
Quench Air
Hardness Rockwell 59c-62c
Applications A2 can be used in the
same applications as both
O1 and W1, but the heat-
treated air-hardening
steels have deeper
hardenability and there is
less movement or
distortion during heat
treatment.
S-7 Tool Steel
Heat treat 1725-1750 F
temperature
Quench Air or Oil
Hardness Rockwell 55c-57c
Applications S7 is good for general
tooling and molding
applications. It possesses
high toughness and shock
resistance.
Disadvantages While S7 is very tough
compared to other tool
steels, it doesn't have
hardness comparable to
the other tool steels.
D-2 Tool Steel
Heat treat 1600-1650 F
temperature
Quench Air or Oil
Hardness Rockwell 60c-62c
Applications D2 has high wear
resistance, good
toughness, and low
distortion. It is often
chosen when long tool life
is required.
Selection of Tool & Die Steels
Introduction
The success of a metal forming tool depends on optimizing all the factors
affecting its performance. Usually, operating conditions (applied loads, abrasive
environments, impacts, and other factors) determine how well a tool holds up.
Most tool failures are related to such mechanical causes. However, with a variety
of tool steels available for manufacturing metal forming tools, it is often possible
to choose a tool steel with a favorable combination of properties for particular
applications. By comparing the levels of metallurgical properties offered by
different steels, tool users can determine which tool steels are best suited for
fixing or resisting performance problems, or for enhancing tool performance. Tool
steels can be categorized and compared by those properties which have a direct
influence on tool performance: hardness, toughness (impact resistance), and
wear resistance.
Cold work tool steels
• General purpose
&n— O1, A2, D2
• Improved toughness (impact
resistance)
&n— S7, A9
• Improved wear resistance
&n— CruWear, M2
• High performance CPM
&n— 3V, M4, 9V, 10V, T15, 15V
Historically, tool steels used for stamping and forming tools have included A2 and
D2, with occasional use of the high speed steel M2. A2 and D2 are familiar to
most tool builders and tool users as common, general purpose cold work tool
steels. They combine good all-around performance properties for stamping and
forming with low cost, wide availability, and relatively easy fabrication. However,
they sometimes do not provide the level of performance needed for high volume
production. Specifically, where long runs and infrequent regrinding are desired,
other higher alloy tool steels or carbide might be used to upgrade from these tool
steels. Traditionally, other properties, such as impact resistance, may be
sacrificed in order to gain the higher wear properties. Conversely, steels chosen
for their resistance to impact or breakage may not be capable of high wear
resistance. An understanding of these tool steel properties and related issues
permits selection of the optimum steel for most applications.
Before discussing specific grades, it will be useful to discuss generally the
properties of tool materials. The primary properties important to cold work tools
are hardness, toughness, and wear resistance. Each of these properties may be
varied independently in tool steels to some extent, so it makes sense to consider
each separately. In fact, the same properties would be important to consider in
carbide materials as well as steels. An understanding of these properties,
combined with an understanding of what factors limit tool life for a particular tool
(breakage, wear, deformation, etc.), will allow tool users to specify the best
performing grade for nearly any application. Tool users can examine failed tools
to determine which property may have been lacking in a tool, or which properties
should be improved, and what other properties must be considered in alternate
materials with the required improved properties.
Properties of tool steel
• Hardness
&n— resistance to deforming &
flattening
• Toughness
&n— resistance to breakage &
chipping
• Wear resistance
&n— resistance to abrasion &
erosion
Properties of Tool Steels — Hardness
Hardness is a measure of a steel’s resistance to deformation. Hardness in tool
steels is most commonly measured using the Rockwell C test. Hardened cold
work tool steels are generally about 58/64 HRC (hardness Rockwell C),
depending on the grade. Most are typically about 60/62 HRC, although some are
occasionally used up to about 66 HRC.
Hardness vs Compressive Yield Strength
Hardness testers work by using a standardized load to make an indentation in
the test piece, then measuring the size of the indentation. A large indentation
indicates low hardness (material is easily indented). A small indentation indicates
high hardness (material resists being indented). Thus, the material’s resistance
to deforming (compression, indentation) is indicated directly by its hardness.
When different steels measure at similar hardnesses, it is because the hardness
tester made the same size impression in each. Thus, at the same hardness,
different steels have similar resistance to deformation. The hardness test is
basically independent of the grade of steel tested.
Tools which plastically deform in service possess insufficient hardness.
Permanent bending of cutting edges, mushrooming of punch faces, or indenting
of die surfaces (peening) all indicate insufficient hardness. Because a steel’s
resistance to indentation is directly related to the hardness, not the grade,
corrective actions for deformation may include increasing hardness, or
decreasing operating loads. Changing grades will not help a deformation
problem, unless the new grade is capable of higher hardness.
Choosing for Hardness
Small differences in hardness do not usually have a significant effect on the wear
life of tool steels. Different tool steels are used at similar hardnesses, yet offer
significant differences in expected wear life. Thus, hardness is not usually a
primary factor in wear resistance, only in deformation resistance. The wear
resistance of tool steels is more directly affected by their chemical composition
(grade) as discussed below.
Properties of Tool Steels — Toughness
Toughness, as considered for tooling materials, is the relative resistance of a
material to breakage, chipping, or cracking under impact or stress. Toughness
may be thought of as the opposite of brittleness. Toughness testing is not as
standardized as hardness testing. It may be difficult to correlate the results of
different test methods. Common toughness tests include various impact tests
and bend fracture tests.
In impact testing, a small sample is held in a fixture and fractured by a moving
impacter, such as a calibrated weight on a pendulum. Toughness is reported as
the amount of energy, usually measured in foot-pounds or joules, that the sample
absorbs before it breaks. Brittle materials will absorb little energy before
fracturing. In bend fracture testing, a fixtured sample is subjected to gradually
increasing amounts of pressure, usually side or bending pressure, until it breaks.
Methods of Toughness Testing
Most tool steels are notch-sensitive, meaning that any small notch present in the
sample will permit it to fracture at a much lower energy. Solid carbide is even
more notch-sensitive than tool steels. Thus, in addition to inherent material
properties, the impact resistance of tool components is significantly impaired by
notches, undercuts, geometry changes, and other common features of tools and
dies.
In service, wear failures are usually preferable to toughness failures (breakage).
Breakage failures can be unpredictable, catastrophic, interruptive to production,
and perhaps even a safety concern. Conversely, wear failures are usually
gradual, and can be anticipated and planned for. Toughness failures may be the
result of inadequate material toughness, or a number of other factors, including
heat treatment, fabrication (EDM), or a multitude of operating conditions
(alignment, feed, etc.) Toughness data is useful to predict which steels may be
more or less prone to chipping or breakage than other steels, but toughness data
cannot predict the performance life of tools.
Choosing for Impact Toughness
Properties of Tool Steels — Wear Resistance
Wear resistance is the ability of material to resist being abraded or eroded by
contact with work material, other tools, or outside influences (scale, grit, etc.)
Wear resistance is provided by both the hardness level and the chemistry of the
tool. Wear tests are quite specific to the circumstances creating the wear and the
application of the tool. Most wear tests involve creating a moving contact
between the surface of a sample and some destructive medium. There are 2
basic types of wear damage in tools, abrasive and adhesive. Wear involving
erosion or rounding of edges, as from scale or oxide, is called abrasive wear.
Abrasive wear does not require high pressures. Abrasive wear testing may
involve sand, sandpaper, or various slurries or powders. Wear from intimate
contact between two relatively smooth surfaces, such as steel on steel, carbide
on steel, etc., is called adhesive wear. Adhesive wear may involve actual tearing
of the material at points of high pressure contact due to friction.
We often intuitively expect that a harder tool will resist wear better than a softer
tool. However, different grades, used at the same hardness, provide varying
wear resistance. For instance, O1, A2, D2, and M2 would be expected to show
increasingly longer wear performance, even if all were used at 60 HRC. In fact, in
some situations, lower hardness, high alloy grades may outwear higher
hardness, lower alloy grades. Thus, factors other than hardness must contribute
to wear properties.
Hardness of Carbides
Alloy elements (Cr, V, W, Mo) form hard carbide particles in tool steel microstructures.
The amount and type present influence the wear resistance.
• HARDENED STEEL • 60/65 HRC
• CHROMIUM
• 66/68 HRC
CARBIDES
• MOLYBDENUM
• 72/77 HRC
CARBIDES
• TUNGSTEN
• 72/77 HRC
CARBIDES
• VANADIUM
• 82/84 HRC
CARBIDES
Tool steels contain the element carbon, in levels from about 0.5% up to over 2%.
The minimum level of about 0.5% is required to allow the steels to harden to the
60 HRC level during heat treating. The excess carbon above 0.5% plays little role
in the hardening of the steels. Instead, it is intended to combine with other
elements in the steel to form hard particles called carbides. Tool steels contain
elements such as chromium, molybdenum, tungsten, and vanadium. These
elements combine with the excess carbon to form chromium carbides, tungsten
carbides, vanadium carbides, etc. These carbide particles are microscopic in
size, and constitute from less than 5% to over 20% of the total volume of the
microstructure of the steel. The actual hardness of individual carbide particles
depends on their chemical composition. Chromium carbides are about 65/70
HRC, molybdenum and tungsten carbides are about 75 HRC, and vanadium
carbides are 80/85 HRC.
These embedded carbide particles function like the cobblestones in a
cobblestone street. They are harder than the steel matrix around them, and can
help prevent the matrix from being worn away in service. The amount and type of
carbide present in a particular grade of steel is largely responsible for differences
in wear resistance. At similar hardnesses, steels with greater amounts of
carbides or carbides of a higher hardness, will show better resistance to wear.
This factor accounts for differences in wear resistance among, say, O1, A2, D2,
and M4. Ideally, tool steels would contain as much carbide volume as needed for
the desired wear performance. In fact “solid carbide” tooling is typically 85% or
90% tungsten carbide particles, in a matrix of 10% or 15% cobalt to hold them
together. Chemically, the microscopic carbide particles in tool steels are similar
to the carbide particles in solid carbide tools. However, very high amounts of
carbide particles can lead to problems in grinding, or lower toughness. More
comments on the effect of carbides on toughness and grindability are discussed
in the following section: Effect of Steel Manufacturing on Properties.
Because of their high hardness, vanadium carbides are particularly beneficial for
wear resistance. When present in significant amounts, vanadium carbides tend to
dominate other types in affecting wear properties. For instance, M4 high speed
steel’s chemical content is nearly identical to M2 high speed steel, except M4
contains 4% vanadium instead of 2%. Despite the high levels of molybdenum
and tungsten carbides (about 6% tungsten, 5% molybdenum) in each grade, the
small difference in vanadium content gives M4 nearly twice the wear life of M2 in
many environments. In cold work tool steels, the carbide content in general, and
to a limited extent the vanadium content in particular, may sometimes be used as
a rough predictor of potential wear life.
Effect of Carbide Content (esp. VC)
on Wear Resistance
HRC 58-62 except as noted
Steels with high volumes of carbide particles, or high hardness types of particles,
usually exhibit the best wear resistance. Vanadium carbides, because of their
hardness and chemistry, are the most effective at enhancing wear properties;
chromium carbides are among the least effective.
Effect of Steel Manufacturing on Properties
The maximum practical limit to the amount of carbide-forming elements which
may be added to a steel for wear properties depends on the ability to maintain a
reasonable distribution of those carbides throughout the steel’s microstructure.
When steels are manufactured, they are melted in large batches, containing the
desired chemical composition. The batches are poured into ingot molds, and
solidify into castings which are subsequently forged or rolled into bars. During the
solidification process, the carbides are formed. Under conditions of long slow
solidification, these carbides form interconnected “segregated” networks,
because they do not stay dissolved in the liquid steel. Large amounts of carbide
particles result in more segregation, and thus more non-uniformity in the steel
microstructure.
Carbide Size and Distribution
The alloying elements Cr, V, W, and Mo form hard carbide particles in tool steel
microstructures. The amount and type of carbides influence wear resistance.
Carbides are intended to improve wear resistance, but their non-uniform size and
distribution (i.e., segregated networks) can impair toughness and grindability.
Grades containing a high volume of hard carbides, like high speed steels and
high vanadium cold work grades, may be particularly affected.
This carbide segregation causes two basic problems. First, areas of high
concentrations of hard carbide particles may be difficult to grind, resulting in
fabrication difficulties. Second, when these segregated areas are physically
elongated during rolling or forging, they result in a directionally oriented
microstructure, and reduce the material toughness along the transverse direction.
Vanadium levels over about 3% are high enough to cause particular grinding and
toughness difficulties. For this reason, despite its benefits for wear resistance,
vanadium is usually limited to about 2-1/2% max. in conventionally manufactured
tool steels.
The CPM Process
In order to manufacture tool steels with high wear resistance, without
encountering these serious drawbacks, powder metallurgy processes are used to
produce P/M tool steels having high vanadium content. Molten tool steel is
atomized into fine droplets which solidify from the liquid so rapidly that the
carbides are prevented from forming into large segregated networks. The
solidified droplets form powder, which is then loaded into a steel can and
consolidated (the individual powder particles are bonded together under high
pressure), and subsequently forged or rolled into steel bars. The carbides formed
during the extremely rapid solidification are fine in size (2 to 4 microns), and are
uniformly distributed throughout the microstructure. Compare this to the larger
carbides (up to 50 microns or more in size), and the characteristic alloy
segregation or banding which results from conventional steelmaking methods.
The characteristic feature of P/M tool steels is their near complete freedom from
carbide segregation.
Microstructure (Carbides)
CONVENTIONAL CPM
For grades with a high volume of carbides
(high wear resistance)
Effect of Carbide Content (ESP. VC)
on Wear Resistance
HRC 58-62 except as noted
Because the microstructural distribution of carbides in P/M steels is so fine and
uniform, higher amounts of carbide-forming elements may be added. Thus,
higher wear resistance may be developed, without the toughness and grindability
limitations inherent in conventional steelmaking. The P/M process has allowed
the development of grades containing 4%, 5%, 10%, and even 15% vanadium,
offering far greater wear resistance than conventionally produced tool steels.
Because of their high wear resistance, these high vanadium P/M grades are
particularly suitable for high production operations.
In addition, the uniformity of the CPM microstructure provides improved
toughness in CPM versions of conventional tool steels. The CPM versions of the
same grades are more resistant to brittle failures. In fact, most CPM grades
designed for metalforming tools have impact resistance comparable to the lower
wear resistance grades such as D2. Thus, CPM steels may offer simultaneous
improvements in both wear and toughness compared to conventional tool steels.
Toughness, CPM vs Conventional
Heat Treating Benefits of High Alloy Tool Steels
The heat treating process used to harden steels consists of heating them up to a
high temperature (usually 1700/2200°F), then quenching to near room
temperature, and finally reheating to some intermediate temperature for
tempering (300/1100°F). A characteristic of low to medium alloy steels (A2, O1,
D2) is that they soften from their maximum hardness somewhat during
tempering. The amount of softening depends on the temperature exposure and
the individual grade characteristics. To retain maximum hardness (over about 58
HRC), A2 and D2 are usually tempered around 400/500°F. Higher exposures
result in lower hardness. A side benefit of high alloy content, typical of high
speed steels, and most of the high wear resistance CPM steels, is that the
tempering characteristics are changed because of the alloy content. They are
tempered over 1000 F, yet retain their full hardness during this exposure.
Coatings and Surface Treatments
Beneficial surface treatments, including nitriding, titanium nitride coating, etc., are
often applied to tool steels to permit lower friction, better wear resistance, or
other properties. Most of these coatings are applied at temperatures of about
850/1050F. Thus, the treatment process can limit the service hardness of low or
medium alloy steels. However, the higher alloy content steels such as M2, M4 as
well as CPM 3V, 9V, 10V, 15V retain their maximum hardness after such
exposures. Thus, normal surface treatment temperatures have no effect on their
hardness, and tools may be treated without fear of dimensional or hardness
changes. The additional wear protection of a surface treatment may be added,
without sacrificing deformation resistance. The CPM grades provide excellent
substrates for all types of surface treatments.
Choosing Tool Steels Based on Properties
As mentioned above, A2 and D2 are common steels used for metal forming
tools. More highly alloyed grades offer better wear resistance. When choosing
the tool steel for any tool, the required properties for the application should be
considered. What is the workpiece? What is the historical failure mode for current
or similar tooling? Which properties should be increased? What trade-offs may
be required?
For tools requiring high resistance to plastic deformation, hardness should be a
concern. Tools for stamping steel generally need to be about 56/58 HRC
minimum, although some form tools, and tools for non-ferrous work material, may
be softer. Most tool steels are capable of reaching roughly similar hardness
levels (low 60’s HRC), and thus will have similar abilities to resist plastic
deformation. However, some high speed steels, such as CPM Rex T15 and Rex
76, can achieve hardnesses approaching 70 Rockwell C. Keep in mind that in
tool steels, the major mechanism controlling wear properties is the type and
amount of carbide particles present. For this reason, increasing the hardness is
not generally an effective method for increasing the wear life of tools, but only for
minimizing deformation.
For better deformation resistance than A2 or D2 tools (60/62 HRC)
• GOOD
&n— M2, Cru Wear - (62/63
HRC)
• BETTER
&n— CPM M4 - (63/64 HRC)
• BEST
&n— CPM T15 - (64/66 HRC)
&n— CPM Rex 76 - (64/67
HRC)
For tools needing high resistance to chipping or breakage, for instance where
frail geometries or thin projections or sharp notches are a problem, high impact
toughness is required. In general, tool steels, even those with low impact
toughness, are many times tougher than solid carbide. (The toughness of carbide
materials is often measured in inch-pounds, where tool steels are measured in
foot-pounds.) Within the families of tool steels, there is some variation in impact
resistance. Shock-resisting steels, like S7 and A9, are both designed to offer
optimum resistance to breakage. However, they differ in their heat treating
process. S7 cannot generally be coated for improved surface wear properties,
because of its low tempering temperature. A9 is typically tempered at over 900 F,
and thus may be coated by any of the common commercial coating processes.
The maximum hardness of both grades is approximately 58/59 HRC. In
examining alternatives to carbide tools, where chipping is the normal failure
mode, the toughness comparisons among steels are usually moot. In these
cases, the normal recommendation is to use CPM 10V or 15V instead of carbide
in most applications, or Rex T15, Rex 76 or Rex 121 when high hardness is
needed. These grades provide the closest wear and hardness properties to
carbide, while offering the toughness properties of tool steels.
There are several other factors beside inherent material properties which often
contribute to chipping or breakage failures. Tool steels are notch-sensitive
materials. The presence of notches, undercuts, sharp radii, changes in section,
or any geometric features may concentrate applied stress and exaggerate the
material’s tendency to break. All reasonable precautions to avoid unnecessarily
sharp radii should be exercised. In addition, in heat treated and EDM’d tools, the
EDM operation can leave the surface in a condition prone to chipping. Where
EDM’d tools are experiencing chronic chipping or breaking problems, they should
be stress relieved (tempered) after EDM before going into operation, and if
practical the EDM layer should be removed as well (stoned, polished, etc.).
For better impact toughness than D2 tools (20 ft-lbs)
• GOOD
&n— A2 - 45 ft-lbs
• BETTER
&n— CPM 3V - 55/80 ft-lbs
&n— CPM 9V (if lower hardness OK) -
50/70 ft-lbs
• BEST
&n— A9 (coated or nitrided for wear) -
80/100 ft-lbs
&n— S7 ( low wear resistance) - 100/125 ft-
lbs
Hardness and toughness may be considered “step” or “threshold” functions; that
is, as long as the property is high enough to prevent damage (indentation or
breakage), there is no further advantage to increasing the property even higher.
However, wear resistance may be considered a “continuous” function; that is,
continual increases in the wear resistance of the steel will result in increases in
the life of the tool. Thus, upgrading for wear resistance may always offer benefits,
provided other properties are not compromised. When long-term abrasive wear
resistance is desired in a tool (that is, when the basic tool runs well, but a longer
in-service time is desired), a steel with higher wear properties is appropriate. In
this case, nearly all the choices for upgrading will involve steel of higher alloy
content. Several of the high-alloy CPM steels offer wear properties midway
between conventional tool steels, and carbide. In working with abrasive media,
the CPM steels offer very high resistance to wear. However, in situations
generating severe metal-to-metal wear (adhesive wear, or galling), the best
solution is to separate the two metal surfaces. This may involve a lubricant, or
commonly a non-metallic coating (titanium nitride, titanium carbonitride, or other
related ceramic coatings). These coatings reduce the coefficient of friction
between the workpiece and the tool, and reduce the risk of welding or galling
wear. When coatings are not practical, materials offering a combination of high
toughness, high hardness, and resistance to abrasion, such as CPM 3V or CPM
M4, are suggested.
For better wear resistance than D2 tools
• GOOD
&n— CruWear, M2, CPM 3V (2-
3% V)
• BETTER
&n— CPM M4, T15 (4-5% V)
• BEST
&n— CPM 10V, 15V (max V)
Rod and Plate Tool Steels
AISI SAE 0-1
This is an electric furnace melt oil hardening tool steel. A non-shrinking general purpose
tool steel, it has excellent abrasion resistance, toughness and machinability
characteristics.
Analysis C .85-1.00, Mn 1.00-1.40, Si .50, Max, Cr. .40-.60, W.40-.60 Max.
AISI SAE A-2
Fine grain, electric furnace air hardening, 5% chrome tool steel. It is a superior quality
steel which has excellent wear and abrasion resistance properties.
Analysis C.95-1.25, Mn 1.00 Max, Cr 4.75-5.50, Mo .90-1.4, V.15-.50
AISI SAE W-1
W-1 water hardening is the most popular, versatile, and least expensive grade of tool
steel. Its high carbon content allows it to be used often without heat treatment for
maintenance applications. It is a fine grained electric furnace melted commercial grade
tool steel which is supplied in the fully spheroidized 100% decarb free condition.
Analysis C .95-1.05, Mn .30-.40, Si .10-.25
AISI SAE S-7
S-7 Hi-shock tool steel is an excellent chock steel that can be and is often used in hot
work applications where the tool temperature does not exceed 1000 deg. F. This tool
steel combines the qualities of high strength and good ductility for cold and medium hot
work application.
Analysis C .45-.55, Mn .20-.80, Si .20-1.00, Cr 3.0-3.5, V .20-.30, Mo 1.30-1.80
AISI SAE D-2
Fine quality, air hardened, electric furnace melt tool steel. The combination of superior
abrasion resistance and toughness found in D-2 results from its high carbon and high
chromium composition. High chrome is an extraordinary tool steel that can be specified
for the most demanding applications. This is non-free machining tool steel.
Analysis C 1.40-1.60, Mn .60 Max, Cr 11.00-13.00, V 1.10 Max, Mo .70-1.20, Co 100
Max
