STAVAX ESR uddeholm

STAVAX ESR
STAVAX ESR

REFERENCE STANDARD

AISI DIN JIS

DF-2 ARNE O1 1.2510 SKS 3

DF-3 O1 1.2510 SKS 3

XW-5 SVERKER 3 D6 (D3) (1.2436) (SKD 2)

XW-10 RIGOR A2 1.2363 SKD 12

XW-41 SVERKER 21 D2 1.2379 SKD 11

XW-42 D2 1.2379 SKD 11

CARMO CARMO

CALMAX CALMAX

CALDIE CALDIE

ASSAB 88 SLEIPNER

ASP 23 VANADIS 23 (M3:2) 1.3344 SKH 53

ASP 30 VANADIS 30 M3:2 + Co 1.3244 SKH 40

ASP 60 VANADIS 60 1.3241

VANADIS 4 EXTRA VANADIS 4 EXTRA

VANADIS 6 VANADIS 6

VANADIS 10 VANADIS 10

VACRON 40 VANCRON 40

618 P20 Mod. 1.2738

618 HH P20 Mod. 1.2738

618 T P20 Mod. 1.2738 Mod.

718 SUPREME IMPAX SUPREME P20 Mod. 1.2738

718 HH IMPAX HH P20 Mod. 1.2738

NIMAX NIMAX

UNIMAX UNIMAX

CORRAX CORRAX

STAVAX ESR STAVAX ESR 420 Mod. 1.2083 ESR SUS 420J2

MIRRAX ESR MIRRAX ESR 420 Mod.

POLMAX POLMAX

ELMAX ELMAX

RAMAX LH RAMAX LH 420 F Mod.

RAMAX HH RAMAX HH 420 F Mod.

ROYALLOY

PRODAX

PT18 MOLDMAX SC

MMXL MOLDMAX XL

MM40 MOLDMAX HH

ALVAR 14 ALVAR 14 1.2714 SKT 4

8407 2M ORVAR 2M H13 1.2344 SKD 61

8407 SUPREME ORVAR SUPREME H13 Premium 1.2344 ESR SKD 61

DIEVAR DIEVAR

HOTVAR HOTVAR

QRO 90 SUPREME QRO 90 SUPREME

705 4340 1.6582 SNCM8

709 4140 1.7225 SCM4

760 1050 1.1730 S50C

This information is based on our present state of knowledge and is intended to provide general notes on our products and their uses.
It should not therefore be construed as a warranty of specific properties of the products described or a warranty for fitness for a particular
purpose.

Edition 081112

2
 STAVAX ESR

STAVAX ESR
The plastic product is only as good as the surface finish of the mould steel
in which the product is formed. The presence of non-metallic inclusions
and segregation within the steel, limit the polishability of the mould steel.
Thanks to the electroslag remelting (ESR) process that is utilised to
produce Stavax ESR, this steel is capable of being polished to a very high
surface finish. The ESR process is an additional step during the steelmaking,
which ensures very clean steel with low sulphur content (0.003% max.) and
non-metallic inclusions.

Stavax ESR is an excellent choice for small and medium inserts and cores.

Properties
Stavax ESR combines corrosion and wear resistance with excellent
polishability, and offers good machinability.
Advantages
Clean and homogeneous mould steel improves polishability, photoetchability
and texture.
Benefits
Reduce mould maintenance as the mould made of Stavax ESR maintains
its original surface finish over a long period of production.

When compared with non-stainless mould steels, Stavax ESR offers

lower production costs through clean cooling channels that assure
uniform cooling and consistent cycle times.

Especially suitable for applications within the medical industry, optical

industry and for other high quality transparent parts when rust in
production is unacceptable and where requirements for good hygiene
are high.

Stavax ESR is a product within the ASSAB Stainless Concept.

The Stainless Concept is our own programme of metallurgically balanced

stainless grades that has been specially developed and continually expanded
to meet the needs of today’s fast-changing plastic moulding industry. The
problems are well known: rust problems with moulds, surface that need
repolishing, cooling channels that have to be redrilled, and parts that
rust together. Choosing the right product within our Stainless Concept,
which can be used individually or in combination to produce the highest
quality tooling for the full range of moulding applications, will minimise the
problems above.

3
STAVAX ESR

General Applications
Stavax ESR is a premium grade stainless tool steel with Whilst Stavax ESR is recommended for all types of
the following properties: moulding tools, its special properties make it particularly
suitable for moulds with the following demands:
good corrosion resistance
Corrosion/staining resistance
excellent polishability
Moulding of corrosive plastics, e.g., PVC, acetates,
good wear resistance and for moulds subjected to humid working/storage
good machinability conditions.
good dimensional stability during heat treatment Wear resistance
Moulding abrasive/ filled materials, including injection
The combination of these properties provides a steel moulded thermosetting grades. Stavax ESR is
with outstanding production performance. The practical recommended for moulds with long production runs,
benefits of good corrosion resistance of a plastic mould e.g., disposable cutlery and containers.
can be summarised as follows: High surface finish
Production of optical parts, e.g., camera and sunglass
Lower mould maintenance costs lenses. Moulding of medical components, e.g., syringes
The surface of cavity impressions retain their original and analysis vials.
finish over an extended service life. Moulds stored
or operated in humid conditions require no special
protection.
Lower production costs
Since cooling channels are less likely to be affected
by corrosion (unlike conventional mould steels),
heat transfer characteristics, and therefore cooling
efficiency, are constant throughout the mould life,
ensuring consistent cycle times.

These benefits, coupled with the high wear resistance of

Stavax ESR, offer the moulder low-maintenance, long-life
moulds for the greatest overall tooling economy.

Note: Stavax ESR is produced using the Electroslag Stavax ESR is the right choice for lens mould with extreme
Remelting (ESR) technique. The result is a mould steel demand on polishability.
with a very low inclusion level providing excellent
polishability characteristics.

C Si Mn Cr V Recommended
Typical analysis % Type of mould
0.38 0.9 0.5 13.6 0.3 hardness HRC
Standard AISI 420 modified, WNr. 1.2083 ESR,
specification SUS 420J2 Injection moulds for thermoplastics 45-52

Delivery condition Soft annealed to approx. 200 HB Injection moulds for thermosetting 45-52
plastics
Colour code Black / Orange
Compression / transfer moulds 50-52

Blow moulds for PVC, PET etc. 45-52

Extrusion, pultrusion dies 45-52

Stavax ESR core to make disposable polystyrene beakers.

Millions of close tolerance mouldings with a very high surface
finish have been produced.

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 STAVAX ESR

Properties
Physical DATA
Hardened and tempered to 50 HRC.

Temperature 20°C 200°C 400°C

Density
7800 7750 7700
kg/m3

Modulus of elasticity
200 000 190 000 180 000
MPa

Coefficient of
thermal expansion - 11.0 x 10 -6 11.4 x 10 -6
per °C from 20°C

Thermal conductivity
19 20 24
W/m °C

Specific heat
460 - -
J/kg °C
Stavax ESR is a desirable choice for the medical industry, which
*Thermal conductivity is very difficult to measure. operates in “clean room” environments, and cannot accept any
The scatter can be as high as ±15% rust on the moulds.

Corrosion resistance
TENSILE STRENGTH
Stavax ESR is resistant to corrosive attack by water,
The tensile strength values are to be considered as water vapour, weak organic acids, dilute solutions of
approximate only. All samples were taken from a bar nitrates, carbonates and other salts.
(in the rolling direction) with 25 mm diameter.
Hardened in oil from 1025 ±10°C and tempered twice A tool made from Stavax ESR will have good resistance
to the indicated hardness. to rusting and staining due to humid working and storage
conditions, and when moulding corrosive plastics under
Hardness 50 HRC 45 HRC normal production conditions.

Tensile strength, R m 1780 MPa 1420 MPa Note: Special protectants are not recommended
during mould storage. Many protectants are chloride
Yield strength, Rp0.2 1460 MPa 1280 MPa based and may attack the passive oxide film, resulting in
pitting corrosion. Tools should be thoroughly cleaned
and dried prior to storage.

Stavax ESR shows the best corrosion resistance when

tempered at low temperature and polished to a mirror
finish.

The influence of tempering temperature on

corrosion resistance
Increasing corrosion resistance

Corrosion
resistance

Stavax ESR is especially suitable for moulding application 100 200 300 400 500 600°C
requiring good hygiene such as clear plastic beer mug made of Tempering temperature
SAN copolymer.

5
STAVAX ESR

Heat treatment
Soft annealing Hardness, grain size and retained austenite as a
function of austenitising temperature
Protect the steel and heat through to 890°C. Then cool
in the furnace at 20°C per hour to 850°C, then at 10°C Grain size
per hour to 700°C, then freely in air. ASTM Hardness, HRC Retained austenite, %
10 60
Grain size
Stress relieving 9 58
Holding time
8 56 40
After rough machining, the tool should be heated 60 min.
through to 650°C, holding time 2 hours. Cool slowly to 7 54
500°C, then freely in air. 6 52
5 30
50
Hardening 4 48
3 46 Retained
Preheating temperature: 600–850°C. Holding time austenite 20
Austenitising temperature: 1000–1050°C, but usually 2 44 20 min.
1020°C–1030°C. 1 42
40 10
960 980 1000 1020 1040 1060 1080°C
Austenitising temperature
Temperature Soaking time Hardness before
°C minutes tempering
Quenching media
1020 30 56±2 HRC
• Vacuum with sufficient positive pressure
• High speed gas/circulating atmosphere
1050 30 57±2 HRC
• Fluidised bed or salt bath at 250–550°C, then cool in
air blast
Soaking time = time at hardening temperature after the Hardness, HRC Retained austenite, %
tool is fully heated through. • Warm oil, approx. 80°C
60 14
In order to obtain optimum properties 1050°C
for the tool, the
Protect the tool against decarburisation and oxidation during 55
cooling rate should be fast, but not at a rate that gives 12
austenitising. excessive distortion or crack. When heat treating in a
50 10
vacuum furnace, a minimum
1020°Cof 4–5 bars overpressure
is recommended. Temper immediately when the tool 8
45
CCT graph reaches 50–70°C.
40 6
Austenitising temperature 1030°C. Holding time 30 minutes.
35 Retained 4
°C austenite
30 1030°C 2
1100
Austenitising temperature 1030˚C
Holding
25 time 30 minutes
1000 100 200 300 AC400 = 980ºC
500 600°C
1f
Tempering temperature (2 x 2h)
900 AC = 860ºC
1s

800 Pearlite
Carbides
700
Dimensional change, %
600
+0.16
500 +0.12 Cooling
Curve Hardness T800–500
+0.08 HV 10 sec.
No.
400
+0.04 1 649 1
MS 2 634 31
300 0
3 613 105
- 0.04 4 592 316
200
Mf - 0.08 5 585 526
Martensite 6 421 1052
100 - 0.12
1 2 3 4 5 6 7 8 7 274 2101
100 200 300 400
8
500
206
600
4204
700°C
Tempering temperature (2 x 2h)
1 10 100 1 000 10 000 100 000 Seconds

1 10 100 1 000 Minutes

1 10 100 Hours
Air cooling
0.2 1.5 10 90 600 of bars, Ø mm

6
 Grain size
9 58
Holding time
8 56 60 min. 40
7 54
STAVAX ESR
6 52
5 30
50
4 48
3 46 Retained
Holding time austenite 20
2 44 20 min.
1 42
Dimensional
40
changes 10
960 980 1000 1020 1040 1060 1080°C
The dimensional changes duringtemperature
Austenitising hardening and tempering
vary depending on temperatures, type of equipment and
cooling media used during heat treatment.

The size and geomety of the tool are also of essential

importance. Thus, the tool shall always be manufactured
with enough working allowance to compensate for
dimensional changes. Use 0.15% as a guideline for Stavax
ESR provided that a stress relief is performed
Hardness, HRC
between
Retained austenite, %
rough
60 and semi-finish machining as recommended. 14
1050°C
Grain size 55
Dimensional changes during hardening 12
ASTM Hardness, HRC Retained austenite, %
10 60 50 10
Grain size An example of dimensional
1020°Cchanges on a plate, hardened
9 58
Holding time
under
45 ideal conditions 100 x 100 x 25 mm is shown below. 8
8 56 60 min. 40
7 54 40
Hardening from Width Length Thickness 6
6 52 1020°C % % %
35 Retained 4
30
A5preform
50 mould made of Stavax ESR.
Martempered austenite
Min. +0.02 ±0 -0.04
4 48 30 1030°C -0.03
Max. +0.03 - 2
3 46 Retained
Holding time austenite 20 Air hardened
25 Min. -0.02 ±0 ±0
Tempering
2 44 20 min. 100 200
Max. 300+0.02400 500
-0.03 600°C -
1 42 Tempering temperature (2 x 2h)
Choose the tempering temperature according to the 10 Vacuum hardened Min. +0.01 ±0 -0.04
40
hardness required
960 980 by 1000
reference
1020 to1040
the tempering graph.
1060 1080°C Max. -0.02 +0.01 -
Austenitising temperature
Temper at least twice with intermediate cooling to room
temperature. The preferred tempering temperature is Dimensional changes during tempering
Dimensional change, %
250°C minimum. On exceptional occasion, the lowest
+0.16
temperature of 180°C is used for small simple inserts
+0.12
that require a hardness of 52-54 HRC.
+0.08
Tempering graph +0.04
0
Hardness, HRC Retained austenite, %
- 0.04
60 14
1050°C - 0.08
55 12 - 0.12
100 200 300 400 500 600 700°C
50 10 Tempering temperature (2 x 2h)
1020°C
45 8 Note: Dimensional changes during hardening and tempering
should be added together.
40 6

35 Retained 4
austenite
30 1030°C 2

25
100 200 300 400 500 600°C
Tempering temperature (2 x 2h)

Note: The curves as shown in the tempering graph are

valid for small samples. Actual hardness achieved after
hardening and tempering depends on the mould size.
Dimensional change, %
+0.16
Tempering at 250°C is recommended for the best combination
+0.12
of toughness, hardness and corrosion resistance.
+0.08
A combination of high austenitising temperature and low
+0.04 Motorcycle helmet lens made of polycarbonate was initially
tempering
0 temperature <250°C gives a high stress level moulded using AISI 420, but was later moulded using Stavax ESR
in the
- 0.04 mould, and should be avoided. due to the very severe demands on polishability.
- 0.08
- 0.12 7
100 200 300 400 500 600 700°C
Tempering temperature (2 x 2h)
STAVAX ESR

Machining recommendations
The cutting data below are to be considered as guiding Milling
values and as starting points for developing your own
best practice. Face and square shoulder milling

Condition: Soft annealed condition ~200 HB Milling with carbide

Cutting data
parameters
Turning Rough milling Fine milling

Turning Cutting speed

Turning with carbide (vc) 180 - 260 260 - 300
Cutting data with HSS†
m/min
parameters Rough Fine Fine
turning turning turning
Feed (f z)
0.2 - 0.4 0.1 - 0.2
Cutting speed mm/tooth
(vc) 160 - 210 210 - 260 18 - 23
m/min
Depth of cut (ap)
2-4 0.5 - 2
Feed (f) mm
0.2 - 0.4 0.05 - 0.2 0.05 - 0.3
mm/r
Carbide P10 - P20
Depth of cut (ap) P20 - P40
2-4 0.5 - 2 0.5 - 3 designation Coated carbide
mm Coated carbide
ISO or cermet
P10
Carbide P20 - P30
Coated
designation Coated - End milling
carbide or
ISO carbide
cement

†
High speed steel Type of milling
Cutting data
parameters Carbide
Solid High speed
indexable
carbide steel
insert
DRILLING
Cutting speed
High speed steel twist drill (vc) 120 - 150 170 - 230 25 - 301
m/min

Drill diameter Cutting speed (vc) Feed (f)

mm m/min mm/r Feed (f z)
0.01 - 0.022 0.06 - 0.22 0.01 - 0.302
mm/tooth
≤5 12 - 14* 0.05 - 0.10
Carbide
5 - 10 12 - 14* 0.10 - 0.20 designation - P20 - P30 -
ISO
10 - 15 12 - 14 *
0.20 - 0.30
1 For coated HSS end mill, vc~ 45–50 m/min
15 - 20 12 - 14* 0.30 - 0.35 2 Depending on radial depth of cut and cutter diameter

* For coated HSS drill, vc= 20–22 m/min

GRINDING
Wheel recommendation

Carbide drill Soft

Hardened
Type of grinding annealed
condition
condition
Type of drill
Cutting data Face grinding straight wheel A 46 HV A 46 HV
parameters Indexable Solid Carbide
insert carbide tip
Face grinding segments A 24 GV A 36 GV

Cutting speed
Cylindrical grinding A 46 LV A 60 KV
(vc) 210 - 230 80 - 100 70 - 80
m/min
Internal grinding A 46 JV A 60 IV
Feed (f)
0.03 - 0.101 0.10 - 0.251 0.15 - 0.251
mm/r Profile grinding A 100 LV A 120 KV

1 Depending on drill diameter

8
 STAVAX ESR

Electrical discharge machining Polishing

If EDM is performed in the hardened and tempered Stavax ESR has a very good polishability in the hardened
condition, the EDM’d surface is covered with a and tempered condition.
resolidified layer (white layer) and a rehardened and
untempered layer, both of which are very brittle and A slightly different technique, in comparison with other
hence detrimental to the tool performance. It is ASSAB mould steels, should be used. The main principle
recommended to finish with “fine-sparking”, i.e., low is to use smaller steps at the fine grinding and polishing
current, high frequency. For optimal performance, the stages, and not to start polishing on too rough a surface.
EDM’d surface should be ground/polished to remove It is also important to stop the polishing operation
the white layer completely. The tool should then be immediately, after the last scratch from the former grain
retempered at approx. 25°C below the highest previous size has been removed.
tempering temperature.
More detailed information on polishing techniques is
given in the brochure “Polishing of Tool Steel”.
Welding
There is a general tendency for tool steel to crack
after welding. When welding is required, take proper
precautions with regards to joint preparation, filler
Photo-etching
material selection, preheating, welding procedure and
post weld heat treatment to ensure good welding Stavax ESR has a very low content of slag inclusions,
results. making it suitable for photoetching. The special photo-
etching process that might be necessary because of
For best result after polishing and photo-etching, use Stavax ESR’s good corrosion resistance is familiar to all
the recommended filler materials as shown in the table the leading photo-etching companies.
below.

Welding method TIG MMA

Further information
200 - 250ºC (soft annealed ~200 HB)
Preheating
200ºC (hardened 56 HRC) For further information, i.e., steel selection, heat
temperature1
250ºC (hardened 52 HRC) treatment, application and availability, please contact our
ASSAB office* nearest to you.
STAVAX STAVAX
Filler material
TIG-WELD WELD
*See back cover page
400ºC (soft annealed ~200 HB)
Maximum interpass
350ºC (hardened 56 HRC)
temperature2
400ºC (hardened 52 HRC)

20 - 40ºC/h for the first two hours

Postweld cooling
and then freely in air

Hardness after
54 - 56 HRC
welding

Heat treatment after welding

Temper at 10-20ºC below the

Hardened condition
orginial tempering temperature.

Heat through to 890ºC in protected

atmoshpere. Then cool in the
Soft annealed
furnace at 20ºC per hour to 850ºC,
condition
then at 10ºC per hour to 700ºC,
then freely in air.

1 A clean steel with very good polishability gives the final medical
Preheating temperature must be established throughout the tool and must
be maintained for the entire welding process, to prevent weld cracking. product an excellent surface finish.
For hardened and tempered tool, the actual preheat temperature used is
typically lower than the original tempering temperature to prevent a drop
in hardness.
2 The temperature of the tool in the weld area immediately before the second
and subsequent pass of a multiple pass weld. When exceeded, there is a
risk of distortion of the tool or soft zones around the weld.

9
STAVAX ESR

Relative comparison of ASSAB plastic mould steels

RESISTANCE TO FAILURE MECHANISMS AND CRITICAL MOULD STEEL PROPERTIES

Plastic Thermal
ASSAB grade Cracking Wear Corrosion Polishability Machinability
deformation conductivity
618
ROYALLOY
718 HH
NIMAX
CORRAX
POLMAX
MIRRAX ESR
STAVAX ESR
8407 SUPREME
UNIMAX
ELMAX
XW-10

10
STAVAX ESR

11
 STAVAX ESR

† ASSAB TOOL STEELS have been in Asia

since 1945. Our customers associate ASSAB
brand with tooling materials that are high in
quality and consistency.

The ASSAB sales companies and distributors

offer you well assorted stocks in a number
of places covering the Asia Pacific region. To
further shorten the lead time, ASSAB will
mill, grind, drill and even wire-cut the tool
steel to meet your requirements. ASSAB
†
also provides state-of-the-art vacuum heat
treatment services to enhance the steel
properties.

Our engineers and metallurgists are always

ready to assist you in your choice of the
optimum steel grade and the best treament
for each application. We always carry out
material examinations at our local mini
laboratories and at the central laboratory in
Sweden.

Our steel mill in Sweden, Uddeholm Tooling,

is one of the few steelworks in the world
† that is dedicated to the manufacture of tool
steels only. Uddeholm Tooling is certified to
ISO 9001 and ISO 14001.

Qingdao †
ASSAB Tooling (Qingdao) Co., Ltd.

Our forging press is one of the most modern of

†
its kind in the world.

Besides tool steels, the ASSAB services for

tool makers include:
†
Welding electrodes for repair welding
of tools

High strength aluminium for tooling

† purposes

Copper alloys (e.g., beryllium copper)

for inserts in moulds

Alloy machinery steels

Cold rolled strip steels for saws,

compressor valves, coater blades, etc

High Performance Steels (HPS)

Sales office only Granshot