Die Cast Brochure

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Die Casting
Tooling Grades
Including an introduction to
Die Casting Specifications:
NADCA 207-2003
NADCA 207-2006
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R&D
Research and development play a strategic role at Bohler-Uddeholm. We know •
that in depth process and material research is the basis for producing the
highest quality products. In order to keep up with the constant demand for
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improved materials, Bohler-Uddeholm maintains a close intensive cooperation
with universities and research centers and supports the exchange of information •
at all levels.
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The knowledge of our technical experts who are engaged in fundamental
research ultimately results in superior value to our customers. Our research
activities yield the most modern high performance Tool Steels and High Speed
Steels produced by means of Powder Metallurgy production techniques,
Aluminum-Alloyed Tool Steels, Nitrogen Alloyed Tool Steels, Electro-Slag Remelted
(ESR) and Vacuum Remelted (VMR/VAR) Tool Steels and special products.
Pre-tested —
to give you peace of mind
At Bohler-Uddeholm we pre-test our Charpy V-notch toughness levels at our
mills in order to ensure that we meet or exceed applicable specifications. By
taking this additional step you can be assured that our material will consistently
meet your expectations for Bohler-Uddeholm products. Our testing means that
customers could consider eliminating additional qualification testing. Keep a
sample for future reference and simply test for toughness after heat treatment.
This will save you time and money.
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Heat Treatment Alliance
In an effort to continue to add value in our dealings with our customers, we
have now created an alliance of world-class heat treaters to support us in our
commitment to supplying the World’s highest quality tool steels. This alliance
will allow us to supply the highest quality steel and assure our customers
that the best heat treatment practices are being utilized to enhance the
characteristics of our products.
Through this partnership we deliver:
Enhanced customer service
Joint technical support
Joint problem solving
An unmatched commitment
to quality!
HEAT TREATING
METAL FINISHING
207-2003
NADCA 207-2003 introduced two acceptance levels for AISI H13 for the Die
Casting Industry: The Premium Level and The Superior Level.
Premium Level NADCA 207-2003
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The Premium criteria for H13 material under the NADCA 207-2003
Specification does not deal with the steel making practices or the forging
practices of the steel manufacturer. Rather the specification calls for
improved levels of cleanliness, a reduction in micro and macro banding,
and for certification of impact toughness levels at an 8 ft-lbs. average with
a 6 ft-lbs. single minimum value. Combined with NADCA recommended
vacuum austenitizing and pressurized gas quenching choosing steels that
meet this specification can lead to success in production in the die-casting
process.
Bohler W302 ISOBLOC meets the Premium Criteria for NADCA 207-2003.
BOHLER W302 ISOBLOC®
(Premium H13)
This premium H13 grade is an electro-slag remelted (ESR) steel,and with this
process the steel has excellent uniform toughness for hot work applications.
W302 ISOBLOC® is recommended in applications where there is short term
demand on the die material, and heat checking and hot wear are not major
factors in the life of the die.
Superior Level NADCA 207-2003
When dealing with superior grade H13, the steel making process needs to
include secondary refining, either ESR (electro-slag remelting) or VAR (vacuum
arc remelting). Additionally the specification calls for improved levels of cleanliness, a reduction in micro and macro banding, and for certification of impact
toughness levels at 10 ft-lbs. average with 8 ft-lbs. single minimum value. This
type of manufacturing technique combined with NADCA recommended vacuum
austenitizing and pressurized gas quenching can lead to success in production
where high volume production or critical performance in the die-casting process
is required.
Uddeholm Orvar Superior and Bohler W302 Superior meet the Superior
Criteria for NADCA 207-2003.
UDDEHOLM ORVAR® SUPERIOR
(Premium H13)
This H13 was developed to meet the highest criteria for any remelted
H13. This steel is produced by a special melting and refining technique
in order to give mechanical properties with maximum isotropy and is
certified to meet a minimum average Charpy V-notch test result of
10 ft-lbs. at 44-46 HRC. Suitable for a wide variety of hot work
applications, including tools for high pressure die casting, hot extrusion
and press forging. Orvar Superior is produced to meet the criteria up
to 18 inches in thickness.
BOHLER W302 SUPERIOR®
(Premium H13)
This remelted H13 is produced via special melting, refining
and forging techniques to possess excellent toughness,
making it suitable for demanding hot work applications in
dimensions 18 inches and greater in thickness. This material is
certified to meet a minimum average 10 ft-lbs. Charpy V-notch at
44-46 HRC. It is recommended in the larger applications where the maximum
properties in an H13 are required.
207-2006
While H13 is good for most general applications in die casting, alternative grades
are available that can address specific needs within the die casting environment.
NADCA 207-2006 combines the specifications for Premium and Superior
Levels of H13 from NADCA 207-2003, and adds additional controls for other
hot work tool steels. All of the alternative grades must be remelted.
The Premium Level of H13 is now referred to as NADCA Grade “A”, and The
Superior Level is referred to as NADCA Grade “B”.
Bohler W302 Isobloc meets the requirements of Grade “A”
Uddeholm Orvar Superior and Bohler W302 Superior meet the
requirements of Grade “B”.
Grade C: NADCA 207-2006—In applications where higher temper resistance is
required, to minimize the loss of hardness at elevated temperatures, there are
hot work tool steels available to improve the die’s performance. These grades are
based on a 1.2367 chemistry, but they have been enhanced to improve performance as a die casting material.
Uddeholm Dievar and Bohler W403 VMR meet the requirement of
Grade “C” and are included within NADCA 207-2006 specification.
UDDEHOLM DIEVAR®
Dievar® is a high performance chromium molybdenum vanadium alloyed hot work
tool steel which is manufactured using the very latest in production and refining
techniques. Its unique chemistry and manufacturing process offers an unparalleled
combination of resistance to heat checking, gross
cracking, hot wear and plastic deformation. Dievar® is
certified to a minimum, average Charpy V-notch
impact toughness of 14 ft-lbs. (19 J) and a minimum
unnotched impact toughness of 220 ft-lbs. (300 J)
per testing procedures defined in the NADCA documents. For larger cross sections, follow our
guidelines for heat treatment.
BOHLER W403 VMR®
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Using Vacuum Arc Remelting along with chemistry modification to a standard
1.2367 type alloy, this grade has excellent uniformity in terms of mechanical
properties and hot wear resistance. Using a hardening temperature of 1885°F as
a standard practice, it can meet the toughness levels of a Superior H13, but have
better hot wear resistance. This grade can be special ordered from our mill.
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Grade D: NADCA 207-2006—In applications when high toughness is required,
due to gross cracking or heat checking issues, but temper resistance is not as
critical, an H11 type alloy can be considered. These hot work tool steels have a
capability requirement of 14 ft-lbs. minimum average Charpy V-notch toughness
at 44-46 HRC. These grades are also required to be remelted, which further
adds to the overall uniformity of the product.
Bohler W300 Isobloc® and Uddeholm Vidar® Supreme meet the
requirements of Grade “D” and are included within the NADCA
207-2006 specification.
*These grades are special order from our mills.
Grade E: NADCA 207-2006—This category of hot work tool steels contains
those grades which have been modified to enhance the characteristics of the
H11 type alloy. Therefore, these grades are modifications to that alloys contained in Grade D. Further enhancing the toughness of the H11 family, these
grades contain some of the toughest hot work tool steel grades. Modifications
to the refining process through enhanced remelting, and the chemistry changes
make this possible.
Bohler W400 VMR® and Uddeholm Vidar® Superior meet the
requirements of Grade “E” and are included within the NADCA
207-2006 specification.
BOHLER W400 VMR®
Using Vacuum Arc Remelting along with chemistry modification to a standard
H11 type alloy, this grade has excellent uniformity in terms of mechanical
properties. Using a hardening temperature of 1810°F as a standard practice,
it can meet Charpy V-notch toughness values for capability at 44-46 HRC of
18ft-lbs. Our internal testing shows even higher values making this the toughest
hot work tool steel we produce.
UDDEHOLM VIDAR SUPERIOR®
Using pressurized ESR for remelting, along with chemistry modifications to a
standard H11 type alloy, this grade has capabilities much like that of DIEVAR
in toughness criteria. *This grade can be special ordered from our mill.
Other Tooling Material Choices
UDDEHOLM QRO® 90 SUPREME
QRO® 90 Supreme is a premium remelted hot work tool steel with very good
strength and hardness at elevated temperatures. It has excellent heat transfer
characteristics. It is used in smaller dies for brass casting, or in small dies in
aluminum die casting where the temperatures run high during production, and
cracking is not a concern.
BOHLER W360 ISOBLOC®
W360 Isobloc is a remelted hot work tool steel which can be heat treated to a
maximum hardness level of 58 HRC. It is recommended for use in applications
where hot wear resistance and/or resistance to plastic deformation is required.
One such application is in zinc die casting, where a hardness higher than 52
HRC is required, and inserts in aluminum die casting where erosion is the major
issue.
Properties Comparison
Die Casting Hot Work Tool Steels
Automotive Specifications
In addition to specifications such as those created by NADCA, many automotive
OEM’s and other industry leading organizations have crafted their own unique
specification requirements. Bohler-Uddeholm meets or exceeds many of these
specifications and a sampling of the specifications for which we have qualified
material is listed here.
Die-Casting Specifications:
Aallied Die Casting
Amcan Castings Limited
Blue Ridge Pressure Castings, Inc.
Briggs and Stratton Corp.
Burlington Technologies Inc.
DaimlerChrysler
Eastern Die Casting Inc.
Ford Motor Company
Ganton Technologies Inc.
General Motors Powertrain Group
Gibbs Die Casting Corp.
J.L. French Corp.
Madison Kipp Corp.
Magnesium Products
Metalloy
PHB Tool and Die
SPX Contech
Toral Cast
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4902 Tollview Drive
Rolling Meadows, IL 60008
www.bucorp.com
email: [email protected]
Sales:
Tel: (800) 638-2520
© 2006, Bohler-Uddeholm Corporation
BU 100 Rev: 10/13/06
USA