Leader in superior tooling solutions

Leader in superior tooling solutions
ASSAB AUTOMOTIVE CONCEPT
Beijing
Dalian
Tianjin
About ASSAB
Yantai
Qingdao
Changzhou
ASSAB was formed in 1945 to market high quality
tool steel from Sweden, renowned for its remarkable
standards. Headquartered in Singapore, ASSAB
operates from close to 50 sales sites in Asia Pacific
supplying the best steel the market can offer. Together
with its best-in-class metallurgical tooling services and
technical know-how, ASSAB continues to be the leader in
tooling solutions in Asia.
Suzhou
Chongqing
Changsha
Shanghai
Ningbo
Wuhan
Nanchang
Xiamen
Guangzhou
Dongguan
Hong Kong
ASSAB’s presence in China is a one-stop solution for all tooling
requirements. With service centres located in strategic industrial provinces,
and a comprehensive inventory of tool and special steel backed by a full suite of
service capabilities, ASSAB is able to provide tooling solutions from a single site.
In addition, its operations are supported by a fully computerised order management system, customer
relationship management software and radio-controlled vehicle fleet, enabling it to meet the demands of various
industry segments including automotive, white goods and electronics within the shortest lead time possible.
Its specialised service competency spans a spectrum that encompasses machining, heat treatment and tool
design consultancy, high quality PVD coating, laboratory and failure analysis.
ASSAB is the distribution network for Uddeholms AB – a leading Swedish tool steel producer with more than
300 years of experience in the tool steel industry. Together, the two companies service leading multinational
companies (MNCs) across practically all key industrial sectors in more than 100 countries.
ASSAB Automotive Concept
Car Body Die for Advanced High Strength Steel
Fine Blanking Technology
Powder Compacting
High Pressure Die Casting
Hot Stamping
Precision Forging
Automotive Lighting
Value-Added Services
3
5
6
7
9
12
15
17
18
ASSAB is a trademark of ASSAB Pacific Pte Ltd.
The information contained herein 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.
Each user of ASSAB products is responsible for making its own determination as to the suitability of ASSAB products and services.
Edition 150429
2
ASSAB Automotive Concept
Today’s automotive manufacturing industry continues to
face growing challenges as it strives to produce cars that are
both stronger and safer while being lighter and consuming
less fuel. There is also the constant pressure among Original
Equipment Manufacturers (OEMs) for new models to be
launched quickly and at competitive prices.
The ASSAB Automotive Concept is designed to offer
OEMs, Tier 1 suppliers, tool users and tool makers alike,
ways to meet these high tooling demands at reduced
production costs.
POWDER COMPACTING
Gear
VANCRON 40 SUPERCLEAN
VANADIS 4 EXTRA SUPERCLEAN
CALDIE
ASSAB is continually working with key industrial partners
to innovate tooling solutions for high pressure die cast
products, Advanced High Strength Steel (AHSS) parts,
intricate fine blanked and powder compacted components
as well as plastic moulded parts for cars.
With its extensive experience and strategic alliance with
major car manufacturers and suppliers, ASSAB is well placed
to provide quality consultancy on choosing the right tool
steel and value-added service for the most demanding
automotive part requirements.
INJECTION MOULDING
Interior Parts
NIMAX
STAVAX ESR
ASSAB 8407 SUPREME
HOT STAMPING
Structural Parts
QRO 90 SUPREME
DIEVAR
ASSAB 8407 SUPREME
HIGH PRESSURE
DIE CASTING
Body Structure Applications
DIEVAR
VIDAR 1 ESR
ASSAB 8407 SUPREME
COLD FORMING
Seating systems
ASSAB 88
CALDIE
VANADIS 4 EXTRA SUPERCLEAN
INJECTION MOULDING
Head Light
MIRRAX ESR
VIDAR 1 ESR
ASSAB 8407 SUPREME
FINE BLANKING
Brake Parts
CALDIE
VANADIS 4 EXTRA SUPERCLEAN
ASSAB 88
HIGH PRESSURE DIE CASTING
Engine Block
DIEVAR
VIDAR 1 ESR
ASSAB 8407 SUPREME
3
New tooling solutions
for new materials
4
Car Body Die for
Advanced High Strength Steel
Advanced High Strength Steel (AHSS) offers many environmental advantages.
With increasing demands on the reduction of CO2 emissions, the lighter weight
and higher strength of AHSS makes it ideal for crucial components. The trade-off
is that it places higher demands on the tool steel used to form the components.
HIGHER DEMANDS ON TOOL STEEL
The use of AHSS reduces the amount of materials employed, thereby reducing
energy consumption. Previous generations of tool steel are often inadequate
to withstand the stresses and failure mechanisms that inevitably follow with the
switch to AHSS. This requires a tool steel that is stronger and more ductile for
better durability and lower production cost.
TOOL STEEL SELECTION MADE EASY
Cyclic mechanical loading and sliding contact between the tool and the work
material typically results in progressive damages to the active surfaces of the tool.
To maintain quality and extend usage, it is necessary to select the best tool steel
with suitable properties.
ASSAB has a wide range of steel grades to withstand different failure mechanisms,
including breakage, abrasive and adhesive wear and chipping.
PROPERTY COMPARISON TABLE
ASSAB Tool
Steel
Commonly
Used
Hardness
ASSAB XW-42
HRC 58-60
ASSAB 88
HRC 58-64
CALDIE
HRC 58-62
VANADIS
4 EXTRA
SUPERCLEAN
HRC 58-64
Chipping
and Cracking
Resistance
Adhesive
Wear
Resistance
Abrasive
Wear
Resistance
Heat
Treatment
Property
Weldability
Coating
Property
5
Fine Blanking Technology
Safety Belt
Seating System
Fine blanking technology – commonly used in the watch
and clock industry – is increasingly being employed in the
automotive industry particularly for parts with zero-error
tolerance.
More than 60 percent of fine blanked parts are used in
the automotive industry, the majority of which are used
to ensure the excellent working condition of critical parts
such as the seating system, safety belt, brake system or the
airbag.
Fine blanking provides finished parts with smooth-cut edges
and high precision for their intended function without any
additional finishing, unlike normally stamped parts.
For quality and precision of the fine blanked parts, the
choice of high performance tooling materials is critical due
to the complexity of the tools.
The right tool steel reduces maintenance cost and production
downtime resulting in higher overall productivity.
Your
Challenge
Abrasive Wear
Adhesive Wear/Galling
Plastic Deformation
Chipping
Our Best
Solution
ASSAB PM60
SUPERCLEAN
VANADIS 4 EXTRA
SUPERCLEAN
ASSAB PM60
SUPERCLEAN
CALDIE
Our
Alternative
Solutions
ASSAB PM30
SUPERCLEAN
ASSAB PM30
SUPERCLEAN
ASSAB PM30
SUPERCLEAN
VANADIS 4 EXTRA
SUPERCLEAN
VANADIS 4 EXTRA
SUPERCLEAN
CALDIE
VANADIS 4 EXTRA
SUPERCLEAN
ASSAB PM30
SUPERCLEAN
6
Powder Compacting
ASSAB’s range of steel for powder compacting can increase the lifespan of tools significantly, compared to tools made
from conventional tool steel or high speed steel.
Achieve superior results in your powder compacting process by using various combinations of ASSAB tool steel
with different properties. This in turn will improve quality, shorten production lead time and meet all manufacturing
requirements. Furthermore, they are all easy to heat treat and maintain good dimensional stability.
CHOOSE THE RIGHT TOOL STEEL
ASSAB Tool Steel
Chipping and Cracking
Abrasive Wear
Adhesive Wear
Compressive
Strength
VANCRON 40
SUPERCLEAN
VANADIS 4 EXTRA
SUPERCLEAN
CALDIE
UNIMAX
7
Best-in-class
for hot work tool steel
8
High Pressure Die Casting
Improving tooling economy in high pressure die casting as well as hot
forging and hot stamping is one of the key drivers behind developing new
grades of tool steel. This development is important to satisfy automotive
industry demands for vehicles that are stronger and safer, yet lighter and
more eco-friendly. This results in an increased use of Advanced High
Strength Steel (AHSS) and high strength aluminium in structural and
safety related components.
TOOLING MATERIAL FOR HIGH PRESSURE DIE CASTING
High pressure die casting offers an economical way of producing
large quantities of complex, high tolerance parts in aluminium and
magnesium alloys.
Long production runs also require dies that last longer. As tooling cost
comprises only about 10 percent of the total cost of the finished aluminium
die cast product, it is not advisable to cut corners with inferior die steel.
Using the most suited tool steel for the specified jobs can in fact favourably
influence overall tool performance and reduce long-term maintenance
costs. Fewer production interruptions mean higher productivity and
greater efficiency.
For decades, ASSAB has been bringing to the market tooling solutions for
advanced hot work die steel, while offering consultancy on choosing the
right steel and service for high pressure die casting technology.
QUICK FACTS
DIEVAR is a hot work die steel specially developed to provide the
best possible performance. It possesses a combination of excellent
toughness and very good hot strength, resulting in a superior
hot work die steel with excellent resistance to heat checking,
corrosion, erosion, gross cracking and indentation.
9
DEMANDS ON DIE STEEL FOR DIE CASTING
Die casting dies are exposed to severe thermal and mechanical cyclic loading, which puts high demands on the die material.
A number of phenomena is known to restrict die material, the most critical being thermal fatigue (heat checking), corrosion/
erosion, cracking (total failure) and indentation.
These phenomena are in turn caused by one or several of these factors:
1. Die material of low quality
2. Unsuitable die design and die making process
3. Improper heat treatment process
4. Insufficient surface treatment
5. Incorrect process parameter adopted for die casting
1. Thermal fatigue (heat checking)
2. Corrosion/erosion
3. Cracking (total failure)
Material Loss
mg/cm2
SURFACE TREATMENT
The surface treatment of the die steel is of 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 surfaces as well as
other coating methods also give a certain protection.
1000
ASSAB 8407 SUPREME
48 HRC
Aluminium
735oC
800
600
400
Non-oxidised surface
Oxidised surface
Zinc
500oC
Brass
950oC
200
QUALITATIVE COMPARISON OF RESISTANCE TO DIFFERENT DIE FAILURES
ASSAB Tool Steel
DIEVAR
ASSAB 8407 SUPREME
QRO 90 SUPREME
10
Heat Checking
Erosion
Gross Cracking
Indentation
DIE ECONOMY
As tooling cost makes up about 10 to 25 percent of the total cost of the finished aluminium die cast product, it is
important to pay for premium die steel to increase tool life.
The most important factors that govern tool life are die material, heat treatment and the die casting process. The tool
steel material in a die casting die accounts for 10 to 20 percent of the die cost while the heat treatment cost is about 5
to 10 percent.
Application: Die insert for automotive engine block
Material: DIEVAR
Material hardness: HRC 44-46
Working material: Alloy 380 (Aluminium Alloy)
Solution: DIEVAR
Die insert steel
H13 ESR
DIEVAR
Die insert life
70,000 shots
130,000 shots
ECONOMICAL EVALUATION OF DIE INSERT FOR AUTOMOTIVE ENGINE BLOCK
7000000
6000000
– H13
– DIEVAR
TOTAL COST
5000000
4000000
3000000
2000000
1000000
0
50000
100000
150000
200000
250000
300000
350000
NUMBER OF PRODUCED PARTS
11
Hot Stamping
Advanced High Strength Steel (AHSS) has become a staple of today’s modern automotive industry. Environmental
requirements as well as higher safety standards make it a key solution for manufacturers aiming for the winning
combination of reduced weight and higher strength.
Until recently, cold forming was the dominating method for making critical structural components in high strength
steel. This has recently been supplemented by hot stamping, the new game-changing technique which places new
demands on the tool steel used in the process.
TOOL STEEL PROPERTIES
Hot stamping tool steel has to be
able to withstand specific failure
mechanisms involved in hot
stamping.
12
Property
Enables
Good wear resistance at elevated
temperature
Abrasion resistance
Very good thermal conductivity
Reduced cycle time with
ensured product quality
Good ductility and toughness
Cracking resistance
Excellent machinability
Lower tool manufacturing costs
Good surface treatment properties
Adhesion, abrasion resistance
TOOL STEEL SUITED
FOR HOT STAMPING
ASSAB produces several tool steel
grades perfectly suited for tools
used in hot stamping. Hot stamping
already means a great advantage over
traditional production methods. By
choosing the right tool steel you can
maximise this advantage.
STEEL GRADES FOR
TRIMMING DIES
ASSAB can provide suitable tool
steel with excellent wear and
chipping resistance for processes
using mechanical trimming dies to
significantly reduce production cost.
ASSAB Premium
QRO 90 SUPREME
Focus on increased
thermal conductivity
DIEVAR
For optimal tool
performance
ASSAB Basic
ASSAB 8407 SUPREME
For increased tool performance
Competitive
Basic
W.-NR. 1.2344 ESR/
AISI H13 Premium
ASSAB Tool Steel
Abrasive
Wear
UNIMAX
Focus on increased
wear resistance
Adhesive
Wear
Chipping
VANADIS 4 EXTRA
SUPERCLEAN
CALDIE
W.-NR. 1.2379/AISI D2
QUICK FACTS
The manufacturing of tool steel and customer demand on tool life
are important aspects when choosing the right product for use in hot
stamping production.
13
Premium tool steel – lower costs per part
14
Precision Forging
In hot forging, a heated billet is pressed between a die set to form a nearly finished product. Large numbers of solid
metal parts are produced in steel, aluminium and copper alloys whose irregular shapes need to be combined with
superior die mechanical properties to avoid premature failure.
Just as in any other production process that uses tool
steel, hot forging requires optimal tool steel properties
for better durability of the die. When selecting tool
steel for hot forging dies, hardenability, toughness,
ductility and temper resistance are some of the most
important properties.
HRC
Formvar
H13/1.2344
600 øC
Formvar, specially developed for hot forging,
possesses good tempering resistance and hot yield
strength to increase tool life over traditional H13/H11
dies.
H
The graph shows how Formvar resists softening at
high temperature over time compared to H13, hence
providing good resistance against hot wear and plastic
deformation leading to longer tool life and cost
effective production.
Difference in tempering back resistance between Formvar and H13.
TOOL STEEL GRADES PERFECTLY SUITED FOR HOT FORGING
The key to choosing a good forging tool steel is to identify the most common problem in any particular die.
ASSAB Tool Steel
Hot Wear
Plastic Deformation
Premature Cracking
Heat Checking
QRO 90 SUPREME
UNIMAX
DIEVAR
ASSAB 8407 SUPREME
ASSAB 8407 2M
ALVAR 14
FORMVAR
15
High surface finish
in a new light
16
Automotive Lighting
Lower fuel consumption and reduced CO2 emissions place demands on vehicle weight reduction. This, coupled
with short lead time and severe pressure on prices, means that the change from metal to plastic parts is becoming
increasingly important.
Also increasing are the demands for reinforced higher strength plastic vehicle parts. Parts are also becoming larger and
the surface requirements more challenging.
OPTIMAL TOOL STEEL LOWERS COST
Larger tools require tooling materials with good hardenability to achieve a high degree of toughness after heat
treatment.
Other properties needed to produce plastic moulds of high quality include high polishability, high corrosion resistance,
wear resistance and high thermal conductivity. For best results, select the optimal tool steel for the respective
application to maximise tool life and performance, giving the lowest possible total tooling cost per part produced.
AUTOMOTIVE LIGHTING
Selection of tool steel for plastic moulds in automotive lighting, such as the headlights of a car is of vital importance.
The ASSAB product programme for large plastic moulds includes several steel grades perfectly suited for the tough
demands of the automotive industry. Vidar 1 ESR for instance, is especially ideal for large moulds requiring a high
surface finish, polished or etched and corresponds to the standard preferred grade used for automotive lighting.
QUICK FACTS
Other steel grades suitable for big moulds in the ASSAB portfolio include Mirrax ESR, and the pre-hardened
grades Mirrax 40, Nimax and ASSAB 718. For very high demands on wear resistance, ASSAB’s range of
powder metallurgical steel grades is also suitable for plastic moulding.
REFLECTOR:
MIRRAX ESR
ASSAB 8407 SUPREME
VIDAR 1 ESR
HOUSING:
NIMAX
ASSAB 718HH
LENS:
VIDAR 1 ESR
ASSAB 8407 SUPREME
MIRRAX ESR
NIMAX
EXTENSION:
VIDAR 1 ESR
ASSAB 8407 SUPREME
MIRRAX ESR
NIMAX
17
Value-Added Services
ASSAB is unmatched as a one-stop product and service provider that offers superior tooling solutions globally. In
addition to the supply of tool steel and other special steel, its range of comprehensive value-added services, such as
machining and heat treatment, spans the entire supply chain to ensure convenience, accountability and optimal usage
of steel for customers. It is committed to achieving solutions for its valued Original Equipment Manufacturer (OEM)
partners, with a constant eye on time-to-market and total tooling economy.
MACHINING
We pre-machine tool steel for the toolmakers to simplify
handling and preparation, saving them time and cost.
SUBZERO TREATMENT
A process to enhance wear resistance and dimensional
stability of the tools during the service period.
CNC MACHINING
We have experienced CNC machining teams that can
provide the machining services for the production of
mould inserts, mould components, fixtures as well as other
machining services.
OXIDISING
For greater durability, oxidising is performed for a surface
layer to protect the cavities of aluminium die casting dies
from erosion and corrosion attack.
HARDENING AND TEMPERING
NITRIDING
After hardening, the steel is brittle and needs to be
tempered to precise levels that meet specific tooling needs.
ASSAB’s vacuum hardening process delivers superior steel
with minimal distortion and optimum property.
In addition to a hard surface layer that is resistant to
wear and erosion, a nitrided surface can also increase the
corrosion resistance for non-stainless grades.
18
PVD COATING
ASSAB coating services feature the most advanced coating
equipment, offering a full range of high quality PVD
(Physical Vapour Deposition) coatings for special steel
products. By using ASSAB coating services you will achieve
improved wear resistance among many other benefits.
ABP
Using the ABP surface treatment, ASSAB is able to
considerably extend the service life of die casting and
forging dies.
POLISHING
Most cold work applications do not need high gloss
polished tool surfaces, but it is always advantageous to
create functional surfaces for a prolonged tool life. It is
always important to consider the final tool steel surface
quality in relation to the application. If a high quality
surface coating is going to be applied, then it is always
recommended to perform high gloss polishing of the tool
surface before the coating process.
TECHNICAL CONSULTING
Our corporate philosophy of treating customers as
partners means that we are there for you. Whether it
be troubleshooting, training or provision of technical
literature, we are only a phone call away.
More than just selling steel, we provide solutions to
overcome any process challenges. We improve customers’
competitiveness by advising on the use of the right steel to
meet specific tooling needs.
19
Choosing the right steel is of vital importance. ASSAB engineers
and metallurgists are always ready to assist you in your choice
of the optimum steel grade and the best treatment for each
application. ASSAB not only supplies steel products with
superior quality, we offer state-of-the-art machining, heat
treatment and surface treatment services to enhance steel
properties to meet your requirement in the shortest lead time.
Using a holistic approach as a one-stop solution provider, we are
more than just another tool steel supplier.
ASSAB and Uddeholm are present on every continent. This
ensures you that high quality tool steel and local support are
available wherever you are. Together we secure our position as
the world’s leading supplier of tooling materials.
For more information, please visit www.assab.com