Mold Steel
Transcript of Mold Steel
DOOSAN PLASTIC MOLD STEELCREATING VALUE FOR THE WORLD
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
CONTENTS
PLASTIC MOLD STEELS
HP1A / HP4A(D1) / HP4MA(D2) 6
HIGH QUALITY PLASTIC MOLD STEELS
HP70 / HEMS1A 10
PHYSICAL PROPERTIES 13
MANUFACTURING PROCESS 14
PLASTIC MOLD STEELS
03
INTRODUCTION
PLASTIC MOLD STEELS
Mirror Polishability >
General Products Semi-TransparentProducts
TransparentProducts
Super mirrorfinish ProductsH
ardn
ess
> HP1AHP4A(D1)
HP4MA(D2)
HP70
HEMS1A
Polishing Property(Schematic Diagram)
Doosan’s Plastic Mold Steel “HP”
DOOSAN HEAVY INDUSTRIES & CONSTRUCTION
HP1A
HP4A(D1)
HP4MA(D2)
HP70
HEMS1A
1050Improved
4140Improved
P20Improved
P21Improved
420Improved
S55CImproved
SCM44OImproved
SNCMImproved
Daido’sNAK80
SUS420J2Improved
1.1210Improved
1.2311Improved
1.2738Improved
-
1.2083Improved
DOOSANBRAND D/N
REFERENCE SPECIFICATION
DIN AISI JIS
-
618Improved
718Improved
-
STAVAXImproved
ASSAB
SUPPLIEDCONDITION
APPLICATIONS
Annealed
Prehardened
Prehardened •General purpose large sizemold base
•Core & Cavity•General purpose mold for
Mass-production
•Higher hardness mold•Bumper mold•General purpose mold for
Mass-production
•High grade mold base formirror surface & EDM requirement
•Corrosion resistant precisionplastic mold
•Glass mold & TV brauntube mold
Prehardened
Prehardened
05
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, ship
building to cement industries.
Since being founded, DOOSAN has also supplied plastic mold steels and tool steels to the high technology
sectors such as electric, electromagnetic, optical, telecommunication industries as well as the fields of
semiconductors, 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 patents
for 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. We
will promise satisfaction to all of our customers.
New types of high-quality free-cutting steel for plastic moldings, HP series plastic mold steels, have been
developed 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 new
products can be reduced by a maximum of 40%. Because of special alloy elements in our HP series plastic
mold steels, one can obtain better etching workability, polishing workability and weldability than in many
other products.
As a result, not only is the efficiency of metal mold work improved and the service life of the cutting tools
greatly extended, but one can also make excellent plastic products. HP steels and HEMS1A are high
performance and high-precision plastic mold steel.
Use of our newly developed HP steels and HEMS1A can make a major contribution to the improvement
productivity and rationalization of production.
DOOSAN’s Plastic Mold Steels
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 Photo-
etching
•Adopting new concept in alloy design to make up for weak points with maintaining strong points
•Optimizing quality heat treatments to get mechanical properties.
■ Chemical Compositions
HP1A / HP4A(D1) / HP4MA(D2)
PLASTIC MOLD STEELS
Material 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
Manufacturing Characteristics
Main Concepts of Developing HP4A(D1) & HP4MA(D2)
Quality Properties
(Unit :wt%)
Material HP1A HP4A(D1) HP4MA(D2)
C >0.50 0.25 ~ 0.35 0.25 ~ 0.35
Ni <0.50 0.20~0.50 0.20~0.50
Cr - 1.00 ~ 1.50 1.50 ~ 2.00
Mo - 0.20~0.40 0.30~0.60
SpecialAdded Added
Alloy
■ Mechanical Properties
Material HP1A HP4A(D1) HP4MA(D2)
SurfaceHS 28~33 HRc 28~32 HRc 31~34Hardness
YieldStrength 350 ~ 450 650 ~ 800 750 ~ 900(N/mm2)
TensileStrength 700 ~ 800 800 ~ 900 900 ~ 1100(N/mm2)
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.
■ SegregationHP4A (D1) and HP4MA (D2) are superior to HP1Ain segregation.
HP4A(D1) HP4MA(D2)
HP1A HP4MA(D2)
■ Mechanical Properties Graph
HP1ARepair Welding Manual
DescriptionHP4A(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±20℃HP4A(D1) : 350±20℃HP4MA(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 OC/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)
PLASTIC MOLD STEELS
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
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
HP70
Material
HEMS1A
100 ~ 115
60 ~ 70
120 ~ 135
75 ~ 85
> 17
> 25
> 52
> 50
37 ~ 41
23 ~ 52
Yield Strength(kgf/mm2)
Tensile Strength(kgf/mm2)
Elongation(%)
Reduction of Area(%)
Surface Hardness(HRc)
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
HP70 / HEMS1A
PLASTIC MOLD STEELS
Characteristics
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.
C
HP70
Material
HEMS1A
< 0.25
0.25~ 0.30
> 2.00
≤ 0..30
-
12.00 ~ 12.50
< 0.50
≤ 0.50
Added
Added
Chemical Composition(wt, %)
Ni Cr Mo Special Alloys
■ Chemical Compositions
■ Mechanical Properties
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 Condition
Cutting 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
11
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
PLASTIC MOLD STEELS
■ Heat Treatment
AISI 420 HEMS1A
■ Cleanliness
AISI 420 HEMS1A
■ Corrosion Resistance
Fig. shows workability of polishing and finishing.
Temperature(0C)
Thermalconductivity
(W / m·K)
Specific heat(Cal / g·0C)
Coefficient ofthermal expansion
(10-6 /0C)
HP1A
Material
HP4A(D1)
HP4MA(D2)
HP70
HEMS 1A
100
200
300
400
500
600
100
100
200
300
400
500
600
100
100
200
300
400
500
600
100
100
200
300
400
500
600
100
200
300
400
50.242
48.148
44.799
41.031
-
-
-
-
-
42.287
41.868
40.193
37.263
40.612
40.193
39.356
37.681
33.1176
33.5781
32.9920
31.1917
28.8052
26.0838
22.1482
25.121
26.377
27.214
28.052
-
11.6
11.9
12.4
12.7
0.499
0.513
0.544
0.597
0.644
0.728
0.766
12.89
12.44
13.38
14.01
14.17
14.56
0.116
0.125
0.132
0.138
0.115
0.124
0.131
0.137
0.117
0.126
0.135
0.139
13.76
14.51
15.36
15.81
16.22
16.54
13.87
14.32
14.82
15.58
15.75
16.08
11.82
13.23
14.16
14.64
14.89
15.14
Room temperature
Room temperature
Room temperature
Room temperature
■ Physical Properties
- -
-
-
-
-
-
- -
-
-
-
-
-
- -
-
PHYSICAL PROPERTIES
DOOSAN HEAVY INDUSTRIES & CONSTRUCTION
13
Preliminary HeatTreatment
Machining
Quality Heat TreatmentInspectionShipment
1. Melting > 2. V.S.D(Ingot Making byVacuum Steam Degassing) > 3. E.S.R >
Forging
Melting
VacuumDegassing
Refining Ingot Making inVacuum Condition
Ingot Making
Heating
E.S.R
MANUFACTURING PROCESS
PLASTIC MOLD STEELS
4. Heating > 5. Forging > 6. Heat Treatment > 7. Inspection
Manufacturing Process
GLOBAL NETWORK
Overseas Branches
DOOSAN HEAVY INDUSTRIESAMERICA CORP.Parker Plaza, 10th Floor400 Kelby StreetFort Lee, NJ 07024, U.S.A.Tel 1-201-944-4554Fax 1-201-944-5022, 5053
NEW JERSEY OFFICEParker Plaza, 10th Floor400 Kelby StreetFort Lee, NJ 07024, U.S.A.Tel 1-201-944-4554Fax 1-201-944-5022, 5053
PITTSBURGH OFFICEC/O Westinghouse ElectricCompany, Suite E361B, 4350Northern Pike, Monroeville,PA 15146 U.S.A.Tel 1-412-374-6048Fax 1-412-374-6168
SCHENECTADY OFFICEGeneral Electric Building 33, Room202A One River RoadSchenectady, NY 12345, U.S.A.Tel 1-518-385-5218, 2629Fax 1-518-385-4984
WINDSOR OFFICE20 International DriveWindsor, CT 06095, U.S.A.Tel 1-860-731-6479, 6482Fax 1-860-731-6478
DOOSAN HEAVY INDUSTRIESJAPAN CORP.Mita Kokusai Building, Room 24101-4-28, Mita, Minato-gu,Tokyo 108-0073, JapanTel 81-3-3452-5451~3Fax 81-3-3452-5624
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Overseas Subsidiaries
DOOSAN BABCOCK ENERGY LTD.11 The Boulevard, CrawleyWest Sussex, RH10 1UX, U.K.Tel 44-1293-612-888Fax 44-1293-584-816
DOOSAN HYDRO TECHNOLOGY, INC.912 Chad Lane Tampa, FL 33619 ,U.S.A.Tel 1-813-549-0182Fax 1-813-549-0183
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DOOSAN HEAVY INDUSTRIESVIETNAM CO., LTD. [DOOSAN VINA]No. 1 An Duong Vuong StreetQuangngai City, Quangngai ProvinceVietnamTel 84-55-713-001~7Fax 84-55-713-008
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Doosan Heavy Industries & Construction Co., Ltd. www.doosanheavy.com
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