Tech Uddeholm Die Casting EN
Tech Uddeholm Die Casting EN
Tech Uddeholm Die Casting EN
DIE CASTING
© UDDEHOLMS AB
No part of this publication may be reproduced or transmitted for commercial purposes
without permission of the copyright holder.
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 9, 09.2018
Selecting a tool steel supplier is a key decision for all parties,
including the tool maker, the tool user and the end user. Thanks
to superior material properties, Uddeholm’s customers get reliable
tools and components. Our products are always state-of-the-art.
Consequently, we have built a reputation as the most innovative
tool steel producer in the world.
Uddeholm produce and deliver high quality Swedish tool steel
to more than 100,000 customers in over 100 countries.
Wherever you are in the manufacturing chain, trust Uddeholm to
be your number one partner and tool steel provider for optimal
tooling and production economy.
CONTENTS
Introduction 4
Demands on the die cast product 4
Aspects of die design 5
Die making 6
Die performance 10
Demands on die steel for die casting 12
Die economy 17
Product programme 18
– General description 18
– Chemical composition 19
– Quality comparison 19
Steel and hardneses recommendations 20
Tooling applications | Die casting
4
Tooling applications | Die casting
X
multicavity dies with identical impressions, it
is important that all runners have the same
path length and cross-sectional area and that
the gates and overflows are identical.
The position of the gates and the thick-
ness and width of the land is critical for the
injection speed of metal. The gates should
be designed so that the injected metal flows
smoothly and freely into all parts of the cavi-
ty. Casting metal that is sprayed, instead of
flowed into the cavity, causes bad castings.
Excessive turbulence of casting metal can
In order to reduce the risk of erosion and
cause erosion of the die.
heat checking on the die material near the
gate, the cavity wall or any cores or inserts GUIDELINES FOR SIZING
should be located as far from the gate as
The following are some guidelines for sizing
possible.
a die for aluminium to meet strength require-
COOLING CHANNELS ments:
The location of the cooling channels should 1. Distance from cavity to outer surface
be such that the entire surface of the die >50 mm (2 inch)
cavity has as uniform a temperature as 2. Ratio of cavity depth to total thickness
possible. <1:3
X
3. Distance from cavity to cooling channel
>25 mm (1 inch)
Distance from cavity to cooling channel
at corner >50 mm (2 inch)
4. Fillet radii
Zinc >0.5 mm (0.02 inch)
Aluminium >1 mm (0.04 inch)
Brass >1.5 mm (0.06 inch)
5. Distance from gate to cavity wall
>50 mm (2 inch)
5
Tooling applications | Die casting
6
Tooling applications | Die casting
Aluminium part
for the automotive industry.
7
Tooling applications | Die casting
THERMAL STRESSES
These stresses are created when the die is
heated or quenched. They increase if hea-
ting takes place rapidly or unevenly. The
Cavity part for high pressure aluminium die casting. volume of the die is increased by heating.
Uneven heating can result in local variations
in volume growth, leading to stresses and
distortion.
Preheating in stages is always recommended
in order to equalize the temperature in the
component.
8
Tooling applications | Die casting
WELDABILITY
In many cases, it is important that a die
casting die can be repaired by welding. The
repair-welding of tool steel always entails a
risk of cracking, but if care is taken and
heating instructions are followed, good
results can be obtained.
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Tooling applications | Die casting
10
Tooling applications | Die casting
11
Tooling applications | Die casting
12
Tooling applications | Die casting
FACTORS WHICH cast product, the die shape and size and the
INFLUENCE THERMAL FATIGUE thermal properties of the die material.
Thermal fatigue cracks are caused by a
combination of thermal cyclic stress, tensile
HOLDING TIME AT
stress and plastic strain. If any one of these PEAK TEMPERATURE
factors is not present, a thermal fatigue crack
Longer holding time implies an increased
will neither initiate nor propagate. The plastic
risk of over-tempering and creep of the
strain starts the crack and the tensile stress
die material. This means a reduction of the
promotes the crack growth.
mechanical strength and accordingly a lower
The following factors influence the thermal resistance to mechanical and/or thermal
fatigue: loadings.
• Die temperature cycle
Preheating temperature COOLING RATE
Surface temperature of the die
The rate at which the surface layer cools is
Holding time at peak temperature
of considerable importance. More rapid
Cooling rate
cooling gives rise to greater stresses and
• Basic die material properties leads to cracks at an earlier stage. The
Thermal expansion coefficient choice of coolant is normally a compromise
Thermal conductivity between desired die life and production rate
Hot yield strength but most die casters have switched from
Temper resistance oil-based lubricants to water-based ones
Creep strength for environmental reasons.
Ductility
BASIC DIE MATERIAL PROPERTIES
• Stress raisers
THERMAL EXPANSION COEFFICIENT
Fillets, holes and corners
Surface roughness The thermal expansion coefficient ought to
be low to get low thermal stresses.
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Tooling applications | Die casting
14
Tooling applications | Die casting
ORVAR
1000
SUPREME
48 HRC ALUMINIUM
800
735°C (1355°F)
BRASS
600
ZINC 950°C (1740°F)
500°C (930°F)
400
COMPOSITION OF
THE CASTING METAL
Pure metals attack tool material at a much EROSION BY MOLTEN CASTING METAL
greater rate than commercial alloys. This is Erosion is a form of hot mechanical wear
valid both for zinc (Zn) and aluminium (Al). on the die surface, resulting mainly from the
The corro-sion of the die steel also increases motion of the melt.
when the aluminium melt contains a low iron
Erosion depends upon the velocity of the
content.
melt as it is injected into the die as well as its
tem-perature and composition. Melt speeds
DESIGN OF THE DIE in excess of 55 m/s (180 feet/s ) substantially
increase erosion damage.
Die design is also of importance for corro-
sion. If molten metal is injected at too high A high temperature also affects the situation,
velocity, the lubricant on the surface of the as the surface of the die is more easily tem-
cavity can be “washed” away. Too high a pered back. Hard particles such as inclusions
velocity is usually caused by incorrect and/or precipitated hard silicon particles,
gating design. in hypereutetic aluminium melts containing
more than 12.7% silicon, further increase the
risk of erosion
damage.
Most commonly a combination of corrosion
and erosion damages occurs on the die
surface. The type of damage that is predo-
minant depends largely on the velocity of the
molten metal into the die. At high velocities,
it is normally the erosion damage which is
predominant.
A good tempering back resistance and high
hot yield strength of the die material are
important.
Erosion.
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Tooling applications | Die casting
FRACTURE TOUGHNESS OF
UDDEHOLM DIEVAR AND
UDDEHOLM ORVAR SUPREME
The ability of a material to resist stresses
without unstable cracking at a sharp notch
or crack is called fracture toughness.
The fracture toughness of Uddeholm Dievar
and Uddeholm Orvar Supreme at different
hardnesses are shown in the figure below.
UDDEHOLM UDDEHOLM
100 ORVAR SUPREME DIEVAR
80
60
60
50
40
40
30
20
20 Fracture toughness at room
temperature (centre, short-
transverse direction).
44 45 46 48 44 48 49 HRC
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Tooling applications | Die casting
One of the most advanced specifications Optimum results can only be achieved by
for steel acceptance criteria and heat tre- demanding and paying for premium quality
atment at present is the Special Quality Die all along the line.
Steel & Heat Treatment Acceptance Criteria
STEEL COST
TOOL
COST
DIE MAKING COST
PRODUCTION AND
MAINTENANCE COST TOTAL
PRODUCT
COST
preheating
welding
heat treatm
ent
scrap
n repairs
oductio
lost pr
adjustment
delivery delays
etc., etc
...
“The Cost Iceberg”
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Tooling applications | Die casting
UDDEHOLM
TOOL STEEL
DIEVAR A premium Cr-Mo-V-alloyed hot work die steel with good high tempera-
ture strength and excellent hardenability, toughness and ductility. Suitable
for medium to big dies in aluminium die casting. It meets the require-
ments of NADCA #207-2011.
UNIMAX A premium Cr-Mo-V alloyed steel with a good toughness and ductility up
to a hardness of 58 HRC.
ORVAR SUPREME/ Premium Cr-Mo-V-alloyed hot work die steel (H13) with good resistance
ORVAR SUPERIOR to thermal fatigue. The steel are produced by a special melting and refin-
ing technique. They meet the requirements of NADCA #207–2011.
VIDAR SUPERIOR A premium Cr-Mo-V alloyed hot work die steel (H11 modified) with good
resistance to cracking. It meets the requirements of NADCA #207–2011.
QRO 90 SUPREME A premium hot work die steel with high hot yield strength and good tem-
per resistance. Especially suited for die casting of copper, brass and for
small inserts and cores in aluminium die casting.
IMPAX SUPREME A prehardened Ni-Cr-Mo-steel supplied at 310 HB suitable for die casting
of zinc, lead and tin. Also used as a holder material and prototype dies.
UDDEHOLM
HOLDER STEEL
HOLDAX A prehardened steel with very good machinability supplied at ~310 HB
for clamping and holding plates.
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Tooling applications | Die casting
CHEMICAL COMPOSITION
SUPPLIED
UDDEHOLM ANALYSIS % HARDNESS
TOOL STEEL AISI C Si Mn Cr Mo V Others Brinell
UDDEHOLM
HOLDER STEEL
HOLDAX 4140 modified 0.40 0.4 1.5 1.9 0.2 – S 0.07 ~310
1.2312
QUALTIY COMPARISON
DIEVAR
UNIMAX
ORVAR SUPREME
ORVAR SUPERIOR
VIDAR SUPERIOR
QRO 90 S
UPREME
Qualitative comparison of critical die steel properties.
All steel tested at 44–46 HRC except for Uddeholm Unimax where 54–56 HRC is used.
DIEVAR
UNIMAX
ORVAR SUPREME
ORVAR SUPERIOR
VIDAR SUPERIOR
QRO 90 SUPREME
Qualitative comparison of resistance to different die failures (the longer the bar, the better).
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Tooling applications | Die casting
FIXED INSERTS
ORVAR SUPREME DIEVAR QRO 90 SUPREME
CORES
ORVAR SUPERIOR 46–50 HRC 40–46 HRC
46–52 HRC ORVAR SUPREME
ORVAR SUPERIOR
VIDAR SUPERIOR
44–48 HRC
QRO 90 SUPREME
42–48 HRC
CORE PINS
ORVAR SUPREME QRO 90 SUPREME* QRO 90 SUPREME
46–52 HRC 44–48 HRC 42–46 HRC
QRO 90 HT* QRO 90 HT
SPRUE PARTS
ORVAR SUPREME ORVAR SUPREME QRO 90 SUPREME
48–52 HRC ORVAR SUPERIOR 42–46 HRC
46–48 HRC
QRO 90 SUPREME
44–46 HRC
NOZZLES
STAVAX ESR ORVAR SUPREME QRO 90 SUPREME
40–44 HRC ORVAR SUPERIOR 40–44 HRC
ORVAR SUPREME 42–48 HRC ORVAR SUPREME
35–44 HRC QRO 90 SUPREME ORVAR SUPERIOR
42–46 HRC 42–48 HRC
20
Tooling applications | Die casting
8 4
1 2 3 7 5 3 6 2 1
1 Clamping plates
2 Holder plates
3 Die inserts
4 Fixed inserts
5 Cores
6 Sprue bushing (nozzles)
7 Sprue pin (Spreader)
8 Ejector pins
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Tooling applications | Die casting
22