Tech Uddeholm Die Casting EN

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Uddeholm

tool steels for

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.

Classified according to EU Directive 1999/45/EC


For further information see our “Material Safety Data Sheets”.

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

INTRODUCTION using these premium die steel with closely


specified heat treatment procedures. Further
Pressure die casting offers an economical
improvements have
way of producing large quantities of com-
plex, high-tolerance parts in aluminium,
magnesium, zinc and copper alloys.
DEMANDS ON THE DIE
The continued growth of the die casting
process depends, to a large extent, on the
CAST PRODUCT
greater use of die castings in the automotive Increasing demands on die cast products will
industry, where weight reduction is increa- ensure continued development of die casting
singly important. alloys with higher strength and ductility, im-
proved machinability, weldability and corro-
Long production runs have focused attention sion resistance. The trends in product design
on the importance of obtaining improved are going
die life. During the last years Uddeholm has towards:
occupied a leading role in developing die
materials to meet this demand and that of • larger components
higher die steel specifications. This has • thinner wall thicknesses
resulted in the grades Uddeholm Orvar
• more complicated shapes
Supreme, Uddeholm Orvar Superior,
Uddeholm Vidar Superior, Uddeholm • closer tolerances
QRO 90 Supreme and Uddeholm Dievar.
These factors favor the use of high pressure
Die casters are now experiencing real die casting over other casting methods like
savings in production and tooling costs by low pressure and gravity die casting.

Tool for high pressure aluminium die casting.

Aluminium pump housing


fixed to the filling system, i.e.
runners,gates and overflows.

4
Tooling applications | Die casting

ASPECTS Surface smoothness of the channels is im-


portant, both from the view point of cooling
OF DIE DESIGN and from the view point of strength but also
The design of a die casting die is primarily for the resistance to corrosion.
deter-mined by the shape of the finished
component. But there are a number of RUNNERS, GATES AND OVERFLOWS
aspects involved in the design and sizing To get optimum casting conditions the coo-
of a die which can have an influence and ling system must have a heat balance with
important bearing on die life. “the hot parts” (runners, gates, overflows and
cavities). This means that the design of the
CAVITY runner, gate and overflow system is of great
High-strength steel are extremely notch-sen- importance. In parts which are difficult to fill
sitive. It is therefore important that the cavity in the cavity, an overflow should be located
is designed with smooth changes of sections to help casting metal to flow into this part
and fillets of maximum possible radius. (alternative vacuum assistant casting). In

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

DIE MAKING ELECTRICAL DISCHARGE


MACHINING
When manufacturing a die casting die the
following are of vital importance: The use of Electrical Discharge Machining
(EDM) in the production of die casting dies
• machinability has been firmly established since many
• Electrical Discharge Machining (EDM) years.

• heat treatment Development of the process has produced


significant refinements in operating tech-
• dimensional stability
nique, productivity and accuracy. As an
• surface treatment alternative to EDM’ing high speed machining
is growing.
• weldability
The basic principles of EDM (spark erosion)
MACHINABILITY are electrical discharges between a graphite
The machinability of martensitic hot work or copper anode and the steel, the cathode,
tool steel is mainly influenced by the amount in a dielectric medium. During the process
of non-metallic inclusions like manganese the surface of the steel is subjected to very
sulfides and the hardness of the steel. high temperatures, causing the steel to melt
or vaporize. A melted and brittle re-solidified
As the performance of a die casting die can
layer is formed on the surface and beneath
be improved by lowering the impurities,
that a re-hardened and tempered layer.
i.e. sulphur and oxygen, Uddeholm Dievar,
Uddeholm Orvar Supreme, Uddeholm Orvar The influence of the EDM operation on the
Superior, Uddeholm Vidar Superior and Ud- surface properties of the die steel can in
deholm QRO 90 Supreme are produced with unfavorable circumstances destroy the wor-
an extremely low sulphur and oxygen level. king performance of the die. For this reason
the following steps are recommended, as a
The optimum structure for machining is a
precautionary measure:
uniform distribution of well spheroidized car-
bides in a soft annealed ferritic structure with
as low hardness as possible. The Microdizing EDM OF ANNEALED MATERIAL
process gives Uddeholm Dievar, Uddeholm A Conventional machining.
Orvar B Initial EDM, avoiding “arcing” and exces-
Supreme, Uddeholm Orvar Superior, Udde- sive stock removal rates. Finish with “fine-
holm Vidar Superior and Uddeholm QRO 90 sparking”, i.e. low current, high frequency.
Supreme a C Grind or polish EDM surface. This reduces
homogeneous structure with a hardness of the risk of crack formation during heating
and quenching. Slow preheating, in
approx. 160 HB for Uddeholm Dievar and
stages, to the hardening temperature is
180 HB for Uddeholm Orvar Supreme, Udde- recommended.
holm Orvar Superior, Uddeholm Vidar Supe-
rior and Uddeholm QRO 90 Supreme. The
More information about electrical
steel are charac-terized by a very uniform
discharge machining can be found in the
machinability.
brochure “EDM of Tool Steel”.
General machining data for turning, milling
and drilling of Uddeholm Dievar, Uddeholm EDM OF HARDENED AND
Orvar TEMPERED MATERIAL
Supreme, Uddeholm Orvar Superior, Udde-
A Conventional machining.
holm Vidar Superior and Uddeholm QRO 90
B Hardening and tempering.
Supreme can be found in the product infor-
mation brochures. C Initial EDM, avoiding “arcing” and exces-
sive stock removal rates. Finish with “fine-
sparking”, i.e. low current, high frequency.
D (i) Grind or polish EDM surface.
(ii) Temper the tool at 15–25°C (30–50°F)
lower than the highest previous tem-
pering temperature.

6
Tooling applications | Die casting

HEAT TREATMENT However, by developing the higher tough-


Hot work tool steel are normally delivered in ness in Uddeholm Dievar, Uddeholm Orvar
the soft annealed condition. After machining, Supreme, Uddeholm Orvar Superior and
the die must be heat treated in order to give Uddeholm Vidar Superior the risk of failure is
optimum hot yield strength, temper resistan- considerably reduced.
ce, toughness and ductility. The quenching rate during hardening has
The properties of the steel are controlled by a great significance for Uddeholm Dievar,
the hardening temperature and soaking time, Uddeholm Orvar Supreme, Uddeholm Orvar
the cooling rate and the tempering tempera- Superior, Uddeholm Vidar Superior and
ture. Uddeholm QRO 90 Supreme and for all other
steel of similar type.
A high austenitizing temperature for a die has
a positive influence on the hot yield strength A low quenching rate gives the best possible
and the resistance to softening, which redu- dimensional stability, but the risk for unde-
ce the heat checking tendency. In Uddeholm sirable changes in the microstructure of the
Orvar Supreme, Uddeholm Orvar Superior steel increases.
and Uddeholm QRO 90 Supreme these A too low cooling rate during hardening will
properties can be enhanced by austeniti- reduce the fracture toughness of the steel.
zing at 1050°C (1920°F) instead of 1020°C
A high quenching rate gives the best pos-
(1870°F). For Uddeholm Dievar 1030°C
sible structure and consequently the best die
(1885°F) instead of 1000°C (1830°F) and for
life.
Uddeholm Vidar Superior 1000°C (1830°F)
instead of 980°C (1800°F). The right balance must be found between the
lower costs (less machining) resulting from
On the other hand, a high austenitizing
a low quenching rate and the better die life
tem-perature gives an increased risk of
achieved by using a high cooling rate (high
grain growth, which can cause a reduction
toughness). In most cases a high quenching
in toughness and ductility. Hence the higher
rate is to be preferred where the total eco-
austenitizing temperature should only be
nomy of the die is the major consideration.
used for small dies, cores and core pins.
Decarburization and heavy carburization may
Similarly, a higher hardness has a positive
cause premature heat checking and shall be
effect on heat checking, although a hard-
avoided at all times.
ness exceeding 50 HRC is not recommen-
ded for aluminium die casting and similarly The die should be tempered after cooling to
not exceeding 46 HRC for brass. The risk 50–70°C (120–160°F). A second tempering
of cracking and total failure increases with operation is essential to obtain a satisfactory
higher hardness. structure. The tempering temperature should
be selected to obtain the desired hardness
of the die. A third temper is generally recom-
mended for die casting dies.

Aluminium part
for the automotive industry.

7
Tooling applications | Die casting

DIMENSIONAL STABILITY Distortion takes place because of stresses in


DISTORTION DURING THE the material. These stresses can be divided
HARDENING AND TEMPERING into:
OF DIE CASTING DIES
• machining stresses
When a die casting die is hardened and tem-
per­ed, some warpage or distortion normally • thermal stresses
occurs. This distortion is usually greater • transformation stresses
when using higher austenitizing
temperatures.
MACHINING STRESSES
This is well known, and it is normal practice This type of stress is generated during
to leave some machining allowance on the machin­ing operations such as turning, milling
die prior to hardening. This makes it possible and grinding.
to adjust the die to the correct dimensions
after hardening and tempering by high speed If stresses have built up in a part, they will be
machining, EDM’ing and grinding etc. released during heating. Heating reduces
strength, releasing stresses through local
distortion. This can lead to overall distortion.
In order to reduce distortion while heating
during the hardening process, a stress-re-
lieving operation can be carried out. It is
recommended that the material be stress-re-
lieved after rough machining. Any distortion
can then be adjusted during fine machining,
prior to the hardening operation.

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.

Aluminium die for


the automotive industry.

8
Tooling applications | Die casting

An attempt should always be made to heat PREPARATION BEFORE WELDING


slowly enough so that the temperature rema- Parts to be welded must be free from dirt
ins virtually equal throughout the die. and grease to ensure satisfactory penetration
What has been said regarding heating also and fusion.
applies to quenching. Very powerful stresses
arise during quenching. As a general rule, the WELDING OF
cooling rates should be as fast as possible, SOFT ANNEALED MATERIAL
relative to the acceptable distortion level.
1 Preheat to 325–375°C (620–710°F).
It is important that the quenching medium is 2 Start welding at this temperature.
applied as uniformly as possible. This is Never let the temperature of the tool go below
espe-cially valid when forced air or protecti- 325°C (620°F). Max. interpass temperature
ve gas atmosphere (as in vacuum furnaces) 475°C (885°F). The best way to keep a con-
stant temperature of the tool during welding,
is used. Otherwise temperature differences
is to use an insulated box with thermo-
in the tool can lead to significant distortion. statically controlled electrical elements
Step quenching is recommended for larger, inside the walls.
more complex dies. 3 After welding cool very slowly 20–40°C/h
(35–70°F/h) for the first two hours and then
freely in air.
TRANSFORMATION STRESSES
4 Soft anneal immediately after welding.
This type of stress arises when the mi-
crostructure of the steel is transformed.
This is because the three microstructures in
question—ferrite, auste-nite and martensi- WELDING OF HARDENED
te—have different densities, i.e. volumes. AND TEMPERED MATERIAL

The greatest effect is caused by transfor- 1 Preheat to 325–375°C (620–710°F).


mation from austenite to martensite. This 2 Start welding at this temperature.
causes a Never let the temperature of the tool go
below 325°C (620°F). Max. interpass temper-
volume increase.
ature 475°C (885°F). The best way to keep
Excessively rapid and uneven quenching a constant temperature of the tool during
can also cause local martensite formation, welding, is to use an insulated box with
thermostatically controlled electrical
causing a volume increase locally in a die gi-
elements inside the walls.
ving rise to stresses in some sections. These
3 After welding cool very slowly 20–40°C/h
stresses can lead to distortion and, in some (35–70°F/h) for the first two hours and then
cases, cracks. freely in air.
4 Stress temper 25°C (50°F) below the highest
SURFACE TREATMENT previous tempering temperature for two
Surface treatments like gas nitriding, salt hours.
bath or ion nitriding can have a beneficial
effect like resistance to erosion and soldering
on certain parts of a die casting die, such as WELDING CONSUMABLES
shot sleeves, nozzles, runners, spreaders, Uddeholm QRO 90 Weld (SMAW), Uddeholm
gates, ejector pins and core pins. Different QRO 90 TIG-Weld or Uddeholm Dievar TIG-
steel possess different nitriding properties, Weld. More information about welding and
depending on chemical composition. Other consum-ables can be found in the brochure
surface treatments have also proved benefi- “Welding of Tool Steel”.
cial in die casting applications.

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.

9
Tooling applications | Die casting

DIE PERFORMANCE Further, it is important to note that the impact


strength, i.e. the materials ability to withstand
The life of a die casting die varies conside-
thermal and mechanical shock, is increased
rably depending on the size and design of
significantly during the first shots by proper
the casting, the type of casting alloy, and the
preheating of the tool.
care and main-tenance of the die.
It is essential therefore, that the temperature
The life of a die can be prolonged by suitable
difference between the die surface and the
treatment before and during casting by:
molten metal is not too great. For this reason,
• suitable preheating preheating is always recommended.

• correct cooling The most suitable preheating temperature is


dependent on the type of casting alloy, but
• surface treatment
normally lies between 150 and 350°C (300
• stress tempering and 660°F).

SUITABLE PREHEATING The curves, in the graphs to the left, show


the range within which the material can be
The initial contact between a cold die casting
preheated. It is important not to preheat to
die and the hot casting metal causes a seve-
an excessively high temperature, since the
re shock to the die material. Heat checking
die may become too hot during die casting,
can start at the very first shot and quickly
causing a tempering back of the die material.
lead to total failure.
Observe that thin ribs get hot very quickly.
The following preheating temperatures are
Impact strength recommended:
Preheating DIEVAR
range

VIDAR SUPERIOR Preheating Material temperature

ORVAR SUPERIOR Tin, Lead alloys 100–150°C (210–300°F)


ORVAR SUPREME
Zinc alloys 150–200°C (300–390°F)
QRO 90 SUPREME
Magnesium,
Aluminium alloys 180–300°C (355–570°F)
Copper alloys 300–350°C (570–660°F)

It is important that heating is gradual and


even. Thermostatically controlled heating
100 200 300 400 500°C
200 400 600 800 1000°F systems are recommended.
Testing temperature
When preheating, coolant should be grad-
ually applied in order to obtain a state of
Hot yield
equilibrium. Shock cooling should be avoi-
strength Preheating ded.
range
Dies containing inserts must be heated at
a slow rate so the inserts and holders can
gradually expand together.

QRO 90 SUPREME CORRECT COOLING


DIEVAR
The temperature of the die is controlled via
cooling channels by water or oil and by the
VIDAR SUPERIOR
lubricant on the die surface.
ORVAR SUPREME
and ORVAR SUPERIOR In order to reduce the risk of heat checking,
100 200 300 400 500 600°C the cooling water can be preheated to app-
200 400 600 800 1000 1200°F roximately 50°C (120°F). Thermostatically
Testing temperature
controlled cooling systems are also common.
Cooling water colder than 20°C (70°F) is not
recommended.

10
Tooling applications | Die casting

During breaks longer than a few minutes, the STRESS TEMPERING


flow of coolant should be adjusted so that During die casting, the surface of the die is
the die does not cool down too much. subjected to thermal strains derived from the
variations in temperature; this repeated
SURFACE TREATMENT straining may result in residual stresses being
To avoid metal-to-die contact it is important generated in the surface regions of the die.
that the lubricant (parting compound) adhe- In most cases, such residual stresses will be
res well to the die surface. For example, a tensile in nature and thereby assist initiation
new or recently repaired die should not have of heat checking cracks.
a glossy metal surface. It is therefore a good
Stress tempering the die will reduce the
idea to coat the die surface with a thin oxide
level of residual tensile stress and thereby
film to provide good adhesion for the lubri-
enhance die life. We therefore recommend
cant in the running-in period.
that stress tem-pering shall be performed
The surface of the die can be oxidized by after the running-in period and then after
heating to approx. 500°C (930°F) for one 1000–2000 and 5000–10 000 shots. The
hour procedure is then repeated for each additio-
followed by cooling in air. Heating in a steam nal 10 000–20 000 shots, so long as the die
atmosphere, 500°C (930°F), for 30 minutes exhibits only minor amounts of heat check-
also produces a good oxide film, with suita- ing. However, there is little point in stress
ble thickness. tempering a heat checked die because the
To remove built-up deposits of die lubricants formation of surface cracks in itself reduces
after a period of use, shot peening of the the level of residual stress.
cavity surface is recommended. This treat- Stress tempering is best carried out at a
ment also closes some of the heat checking temperature about 25°C (50°F) below the
cracks. It in-duces compressive stresses highest tempering temperature which has
in the surface layer, which compensate for previously been used during heat treatment
some of the tensile stresses which cause of the die. Normally, two hours holding time
heat checking. Parts which are subjected to at temperature should be sufficient.
abrasion and friction, such as ejector pins
and shot sleeves, may be nitrided or
nitrocarburized for longer life.

Die for brass


die casting.

11
Tooling applications | Die casting

DEMANDS ON Typical thermal fatigue damage is a pattern


of surface cracks known as “heat checking”,
DIE STEEL FOR DIE well-illustrated in the photo below.
CASTING
Die casting dies are exposed to severe
thermal and mechanical cyclic loading, which
puts high demands on the die material. There
are thus a number of phenomena which
restrict die life.
The most important are:
• thermal fatigue (heat checking)
• corrosion/erosion
• cracking (total failure)
• indentation
Much attention has been paid to understan-
The number of shots achievable in a die cas- ding the thermal fatigue process and to relate
ting die is strongly influenced by the working the resistance to heat checking to basic
temperature, i.e. the casting alloy. The die life material properties. For this purpose
for a speci-fic alloy can also vary conside- Uddeholm has built a special device for
rably due to the design of the cast product, simulation of the thermal fatigue damage.
the surface finish, the production rate, the The aim of these efforts is to improve and
process control, the design of the die, the die develop the die material and has resulted in
material its heat treatment and the acceptan- the premium steel grades Uddeholm Dievar,
ce level of size and surface finish variations. Uddeholm Orvar Supreme, Uddeholm Orvar
Superior, Uddeholm Vidar Superior and
THERMAL FATIGUE Uddeholm QRO 90 Supreme.
Thermal fatigue is a gradual cracking due to
thermal stresses from many temperature
cycles and is a micro-scale phenomenon
taking place only in a thin surface layer.
In use die casting dies are subjected to alter-
nate heating and cooling. This gives rise to
severe strains in the surface layer of the die,
gradually leading to thermal fatigue cracks.

Casting temperature Factors which limit Normal life, number of shots


Casting alloy °F °C die life, Die Die Core
Zinc ~800 ~430 Erosion 0.5–2 million 0.5–2 million
Magnesium ~1200 ~650 Heat checking 100 000 50 000
Cracking to to
Erosion 400 000 200 000
Indentation
Aluminium ~1300 ~700 Heat checking 60 000 40 000
Cracking to to
Erosion 200 000 150 000
Indentation
Copper/Brass ~1780 ~970 Heat checking 5 000 1 000
Indentation to to
Erosion 50 000 5 000
Cracking

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.

DIE TEMPERATURE CYCLE


THERMAL CONDUCTIVITY
PREHEATING TEMPERATURE
A high thermal conductivity reduces the
It is essential that the temperature differen-
thermal gradients and thereby the thermal
ce between the die surface and the molten
stresses. It is, however, very difficult to pre-
metal is not too great. For this reason pre-
dict or to investigate experimentally to what
heating is always recommended.
extent the thermal conductivity influences
The preheating temperature should be mini- this matter.
mum 180°C (355°F) for aluminium at which
temperature the fracture toughness is almost
twice as high as at room temperature. HOT YIELD STRENGTH
A high hot yield strength lowers the
plastic strain and is beneficial in resisting
SURFACE TEMPERATURE OF THE DIE heat checking.
The temperature of the surface layer of the
die is very important for the occurrence
of thermal fatigue. Up to 600°C (1110°F) TEMPER RESISTANCE
the thermal expansion and the stresses If a die material with initially high hot yield
are moderate for a normal hot work steel strength becomes softer during use due to
but at higher temperatures the risk of heat high temperature exposure it means that the
checking becomes significant. The surface heat checking damage accelerates. It is the-
temperature of the die is mainly determined refore important that the die material has a
by the preheating temperature, the casting good resistance to softening at high tempe-
temperature of the metal, the design of the rature exposure.

13
Tooling applications | Die casting

CREEP STRENGTH parting lubricant adheres better and is


The softening associated with temper resi- distributed more evenly on the surface. Fur-
stance is clearly accelerated by mechanical ther, less soldering takes place and it gives
load. The die material is exposed both to better release of castings. This is especially
high temperature and mechanical load. It is important during the running-in of a new die.
thus obvious that a good die material will
possess resistance to the joint action of high CORROSION/EROSION
temperature and mechanical load as quan- CORROSION BY
tified by a high creep strength. In fact, it has MOLTEN CASTING METAL
been proven by experiment that heat check- During die casting, the molten metal is
ing cracks also can be produced by constant injected into the die. In cases where the
temperature and cyclic mechanical load. cavity surface lacks a protective layer, the
cast metal will diffuse into the die surface. At
the same time, alloying elements within the
DUCTILITY die (especially iron), will diffuse from the die
The ductility of the die material quantifies the surface into the cast metal. These processes
ability to resist plastic strain without crack- can create both dissolution of the steel and
ing. At the initiation stage of the thermal fati- intermetallic compounds between the cast
gue damage the ductility governs the number metal and the die surface. In cases where
of cycles before visible cracks appear for severe formation of intermetallic compounds
a given hot yield strength and temperature occurs, the cast metal will solder to the die
cycle. At the crack growth stage the ductility surface.
has a declining influence.
Uddeholm has investigated the corrosion
The ductility of the material is greatly influen- tendency in different molten die casting
ced by slag inclusions and segregations, i.e. metals.
the purity and the homogeneity of the steel.
The steel from Uddeholm for die casting dies
are therefore processed in a special way. The FACTORS WHICH
ductility of the steel has been considerably INFLUENCE CORROSION
improved by means of a special melting and A number of factors influence die corrosion:
refining technique, a controlled forging pro- • temperature of the casting metal
cess and a special microstructure treatment.
This improvement is especially pronounced • composition of the casting metal
in the centre of thick blocks. • design of the die

STRESS RAISERS • surface treatment


FILLETS, HOLES AND CORNERS
Geometrical stress concentration and incre- TEMPERATURE OF
ased thermal gradients increase the stresses THE CASTING METAL
and strains at fillets, holes and corners. This The die casting alloys have critical tempera-
means that heat checking cracks start earlier tures above which corrosion attacks increa-
in these areas than on plane surfaces. The se. Zinc starts to react with steel at about
joint action of heat checking cracks and 480°C (900°F) and aluminium at about
fillets increases the risk of total failure of 720°C (1330°F).
the die.
Degree of corrosion

SURFACE ROUGHNESS BRASS


ZINC ALUMINIUM
Surface defects such as grinding scratches
Not Not Not
affect the starting of cracks for the same recomm. recomm. recomm.
reasons as fillets, holes and corners. Within
the recommended grinding range of 220–600
grit, surface roughness should not be a
cause of heat checking. One advantage
400 500 600 700 800 900 1000°C
with a not too highly polished surface, for 750 930 1110 1290 1470 1650 1830°F
example sand blasted or oxidized, is that the Temperature

14
Tooling applications | Die casting

Copper alloys do not seem to have any really SURFACE TREATMENT


critical temperature, but corrosion increases The surface treatment of the die steel is of
slowly with temperature. great importance. If metallic contact between
the die steel and the molten metal can be
avoided, the risk of corrosion is much less.
An oxide film on the surface provides good
protection. Nitrided or nitrocarburized surfa-
ces as well as other coating methods
also give a certain protection.

Material loss Non-oxidized surface


mg/cm2
Oxidized surface

ORVAR
1000
SUPREME
48 HRC ALUMINIUM
800
735°C (1355°F)
BRASS
600
ZINC 950°C (1740°F)
500°C (930°F)
400

Soldering damage on a core pin. 200

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.

15
Tooling applications | Die casting

CRACKING (TOTAL FAILURE) INDENTATION


The toughness of the die material is the Indentation on the parting lines or sinking of
ability to accumulate tensile stresses without the die is normally due to too low hot hard-
cracking at sharp notches or other stress ness.
raisers. The tough-ness of a die is dependent
At elevated temperatures, the strength of the
on the die material
steel and therefore its hardness will diminish.
and its heat treatment. Due to the fact that
This means that the risk of indentation on a
the mechanical and thermal stresses in a die
hot work die will increase with the operating
are spread in all directions the toughness in
temperature of the die. Both the locking
the die has to be considered in all directions
pressure on the die halves and the metal
– longitudinal, transverse and short
injection pressure are so high that a certain
transverse.
high-temperature strength is required. This
Uddeholm Dievar, Uddeholm Orvar Supreme, is especially important for die casting of
Uddeholm Orvar Superior, Uddeholm Vidar aluminium (Al), magnesium (Mg) and copper
Superior and Uddeholm QRO 90 (Cu) alloys.
Supreme are produced by a special
processing technique which improves the
isotropy of the mechanical properties.
Thermal shock is total cracking due to oc-
ca-sional thermal overloading. It is a macro-
scale phenomenon and is one of the most
frequent causes of total damage of the die.

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.

Fracture toughness, KIC


ksi(in)1/2, MPa(m)1/2

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

16
Tooling applications | Die casting

DIE ECONOMY for Die Casting Dies #207–2011 released by


the North American Die Casting Association
The drive for improved tooling economy has
(NADCA).
resulted in the development of “premium
quality” die steel. Further improvement of tooling economy
must involve specifications on the heat treat-
As the tooling cost is in the order of 10–
ment of the die. This should be optimized to
20 per cent of the total cost of the finished
avoid any excessive dimensional changes or
aluminium die cast product, the validity of
distortion but to produce the optimal combi-
paying for premium die steel quality resulting
nation of hardness and toughness. The most
in increased tool life is obvious.
critical factors are the hardening tempera-
The most decisive factors that govern tool ture and the cooling rate during quenching.
life are the die material, its heat treatment Precautions like proper pre-heating of the die
and the die casting process control. The ma- as well as stress tempering will give a better
terial in a die casting die accounts for 5–15 die economy.
per cent of the die cost while the heat treat-
Surface treatments are methods to protect
ment cost is about 5–10 per cent. The picture
the die surface from corrosion/erosion and
below – The Cost Iceberg – shows the steel
thermal fatigue.
cost in relation to total tooling costs.
New welding techniques have opened areas
In order to assure a good steel quality a
for maintenance and repair welding, both
number of material specifications for die
important ways to increase the die life.
material have been developed during the last
20 years. Most of these contain requirements Everyone involved in the chain – steel pro-
on chemical analysis, microcleanliness, mi- ducer, die manufacturer, heat treater and
crostructure, banding, grain size, hardness, die caster – knows that there can be large
mechanical properties and internal sound- variations in quality level at every step of this
ness (quality level). process.

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”

17
Tooling applications | Die casting

PRODUCT PROGRAMME FOR DIE CASTING


GENERAL DESCRIPTION

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.

QRO 90 HT A prehardened QRO 90 Supreme material, supplied at 37–41 HRC


and suitable for core pins.

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.

18
Tooling applications | Die casting

CHEMICAL COMPOSITION

SUPPLIED
UDDEHOLM ANALYSIS % HARDNESS
TOOL STEEL AISI C Si Mn Cr Mo V Others Brinell

DIEVAR – 0.35 0.2 0.5 5.0 2.3 0.6 – ~160


UNIMAX – 0.50 0.2 0.5 5.0 2.3 0.5 – ~185
ORVAR SUPREME H13 0.39 1.0 0.4 5.2 1.4 0.9 – ~180
(1.2344)
ORVAR SUPERIOR H13 0.39 1.0 0.4 5.2 1.4 0.9 – ~180
(1.2344)
VIDAR SUPERIOR H11 modified 0.36 0.3 0.3 5.0 1.3 0.5 – ~180
(1.2340)
QRO 90 SUPREME – 0.38 0.3 0.8 2.6 2.3 0.9 Micro-
alloyed ~180
IMPAX SUPREME P20 modified 0.37 0.3 1.4 2.0 0.2 – Ni 1.0 ~310
1.2738

UDDEHOLM
HOLDER STEEL
HOLDAX 4140 modified 0.40 0.4 1.5 1.9 0.2 – S 0.07 ~310
1.2312

QUALTIY COMPARISON

UDDEHOLM TEMPER HOT YIELD HARDENA-


TOOL STEEL RESISTANCE STRENGTH DUCTILITY TOUGHNESS BILITY

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.

UDDEHOLM HEAT GROSS


TOOL STEEL CHECKING CRACKING EROSION INDENTATION

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).

19
Tooling applications | Die casting

STEEL AND HARDNESS RECOMMENDATIONS


DIE PART TIN/LEAD/ZINC ALUMINIUM/MAGNESIUM COPPER, BRASS

CLAMPING PLATES HOLDAX HOLDAX HOLDAX


HOLDER PLATES (prehardened) ~310 HB (prehardened) ~310 HB (prehardened) ~310 HB
IMPAX SUPREME IMPAX SUPREME IMPAX SUPREME
(prehardened) ~310 HB (prehardened) ~310 HB (prehardened) ~310 HB

DIE INSERTS IMPAX SUPREME DIEVAR QRO 90 SUPREME


~310 HB 44–50 HRC 40–46 HRC
ORVAR SUPREME ORVAR SUPREME ORVAR SUPREME
ORVAR SUPERIOR ORVAR SUPERIOR ORVAR SUPERIOR
46–52 HRC VIDAR SUPERIOR 40–46 HRC
UNIMAX 42–48 HRC
52–56 HRC UNIMAX**

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

EJECTOR PINS QRO 90 SUPREME QRO 90 SUPREME QRO 90 SUPREME


ORVAR SUPREME ORVAR SUPREME ORVAR SUPREME
46–50 HRC (nitrided) 46–50 HRC (nitrided) 46–50 HRC (nitrided)

PLUNGER ORVAR SUPREME ORVAR SUPREME QRO 90 SUPREME


SHOT SLEEVES 42–46 HRC (nitrided) ORVAR SUPERIOR 42–46 HRC (nitrided)
42–48 HRC (nitrided) ORVAR SUPREME
QRO 90 SUPREME ORVAR SUPERIOR
42–48 HRC (nitrided) 42–46 HRC (nitrided)
* Surface treatment is recommended
** For small Mg die inserts where a good erosion resistance is needed.

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

21
Tooling applications | Die casting

22

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