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Material Grades Raw Materials MATERIAL GRADES RAW MATERIALS HIGH-QUALITY RAW MATERIAL Not all steel is the same. This is why we select the best-known steel- works as our suppliers. Only the best raw materials ensure exceptionally good products. It is ultimately you as the customer who benefits from this quality. QUALITY NEEDS TO BE CHECKED We carry out in-house spectral analyses, strength tests and ultrasonic tests. Only flawless steel will pass these quality control measures. 2 STRESS-RELIEVING HEAT TREATMENT THREE FURNACES FOR 240 TONNES OF STEEL During the production of steel plates tension grows in the material from various machining processes – caused, for example, by irregular temperature. At Meusburger all steel plates are heat-treated for stress relief in one of the three furnaces for 24 hours. The daily capacity is 240 tonnes. LOWERING TENSION With stress-relieving heat treatment, the tension in the material is minimised without changes to the microstructure or strength. This is a great advantage during subsequent machining. If there was still tension in the material, it would, for example, cause deformation during sawing or milling. During stress relieving it is important to heat the plates slowly and consistently and then maintain this temperature for 6 hours. This guarantees that thick plates are also heated through to the core. °C The Meusburger 700 heat treatment process 600 500 400 300 200 100 20 h 0 heating maintaining cooling 24 4 h 6 h 14 h = 35 °C / h COOLING FOR 14 HOURS The subsequent slow, regular cooling period of 14 hours in the furnace is even more important. Here the plates are cooled by approximately 35°C per hour. If they were cooled more quickly, tension - and even the formation of cracks - could once more occur in the material. 3 NOT ALL STEEL IS THE SAME MATERIAL GRADES Unalloyed steel Steel for case-hardening Pre-toughened steel Corrosion resistant steel 1.0577 1.2162 1.2311 1.2083 1.1730 1.7131 1.2312 1.2083ESU 1.2714HH 1.2085 1.2738 1.2316 1.2085 1.2316 1.2738TSHH Steel for through hardening HSS HSS high speed / Cold-work steel Hot-work steel High-speed steel powder steel 1.2083 1.2343 1.3343 1.3344PM 1.2083 ESU 1.2343 ESU MV10PM 1.2210 1.2344 MW10PM 1.2363 1.2344 ESU 1.2379 1.2714 1.2767 1.2842 Quenched and Carbides Non-ferrous metals tempered alloy steel 1.7225 CF-H40S+ 3.3547 3.4365 4 COLD-WORK STEEL Cold-work steels are used for moulds which generally don’t reach temperatures higher than 200°C while in operation. HOT-WORK STEEL The continuous operating temperature of hot-work steel is over 200°C, which is why hot-work steel offers the best properties for die casting moulds as well as moulds with which high performance plastics are processed. STEEL FOR CASE-HARDENING Due to the low carbon content of steels for case-hardening, they are “inserted” into an atmosphere with high carbon content and heated. The result is a piece with high core toughness and surface hardness. TEMPERED STEEL These steels are delivered already quenched and tempered. High tensile and fatigue strength are the distinguishing features of this material. STEEL FOR THROUGH HARDENING Steels for through hardening are delivered in a soft condition. They are good for further hardening processes,in order to change the mechanical properties of the steel. HIGH-SPEED STEEL High-speed steels, or HSS for short, are high-alloy tool steels with large amounts of alloying elements such as tungsten, molybdenum, chrome, and vanadium. They offer high resistance to adhesive and abrasive wear with high toughness as well as high resistance to pressure and high temperatures. 5 6 Alloying elements Element Melting point Importance This is the strongest and very frequently used deoxidation and denitriding compound ALUMINIUM (AL) 658 °C which supports the steel during its ageing. Since aluminium nitrides with nitrogen to produce a very hard compound, it is usually used as an alloy in nitriding steel. CARBON (C) 3450 °C Carbon is the most important and indispensable alloying element in steel. Cobalt is always used together with other alloying elements such as chromium and COBALT (CO) 1492 °C tungsten. It increases the hot hardness and wear resistance in high speed steel. Chromium forms hard carbides, which increases the wear resistance and the durability CHROMIUM (CR) 1920 °C of cutting edges. At the same time it facilitates through hardening. Copper is used as an alloying element for only a few steel grades because it accumulates below the scale layer and can penetrate the grain boundary of the steel COPPER (CU) 1084 °C causing very fragile surfaces in hot forming processes. It is sometimes considered to have a damaging effect on steel. Manganese binds sulphur to manganese sulphides and thereby reduces the adverse effects of the iron sulphide. All steel grades contain small amounts of manganese in MANGANESE (MN) 1221 °C order to facilitate casting, rolling and forging. It is considered an alloying element only if its content is greater than 0.5%. Molybdenum is usually used together with other alloying elements. It works like MOLYBDENUM (MO) 2623 °C chromium but is stronger. In combination with chromium it results in a higher hot hardness. Nickel gives cold work steels a higher toughness. Engineering steels contain nickel NICKEL (NI) 1453 °C in combination with chromium and molybdenum in order to improve their strength. PHOSPHOR (P) 44 °C This strong alloying element usually has a damaging effect on steel. Sulphur has a low solubility in iron but forms stable sulphides with some other alloying SULPHUR (S) 118 °C elements. Manganese sulphides are favourable because they have a positive effect on machining. This is included in all steel grades in order to facilitate the processing of the steel. It is SILICON (SI) 1414 °C considered an alloying element only if its content is greater than 0.5%. Vanadium is a good carbide former. It binds nitrogen and has a refining eff ect on the VANADIUM (V) 1726 °C crystals. The result is a finer structure. The hard carbides increase the heat resistance, wear resistance and resistance to tempering. Tungsten forms hard carbides with very good cutting properties and also provides a TUNGSTEN (W) 3380 °C high hot hardness. The tensile strength, yield strength, wear resistance and toughness can be increased with Tungsten. 7 Overview of material grades Indicatory Material no. Designation Strength Character Application analysis DIN: S 355 J2 (St 52-3) C ≤ 0.22 Structural steel For common applications in mould and die 1.0577 AFNOR: A 52 FP Si ≤ 0.55 ≈ 550 N/mm² unalloyed, with good weldability making and machine and jig construction AISI: A738 Mn ≤ 1.60 Tool steel Unhardened parts for mould, die and DIN: C 45 U C 0.45 unalloyed, suitable for flame hardening jig construction or plates and frames for AFNOR: XC 48 Si 0.30 ≈ 640 N/mm² 1.1730 mould bases and die sets AISI: 1045 Mn 0.70 C 0.40 Steel for through hardening Cavity plates and inserts for the processing DIN: X 40 Cr 14 Si 0.40 low corrosion, high-alloy of plastics, mainly for the processing of AFNOR: Z 40 C 14 ≈ 720 N/mm² 1.2083 Mn 0.30 corrosive plastics AISI: 420 Cr 13.00 C 0.40 Steel for through hardening Cavity plates and inserts for the processing DIN: X 40 Cr 14 1.2083 ESU Si 0.40 low corrosion, suitable for mirror polishing, of plastics, mainly for the processing of AFNOR: Z 40 C 14 ≈ 720 N/mm² Mn 0.30 electro-slag remelted, high-alloy corrosive plastics AISI: 420 ESR (ESR) Cr 13.00 C 0.33 Tool steel Plates for corrosion resistant mould bases Si 0.30 pre-toughened, corrosion resistant, with and die sets; moulds for corrosive plastics DIN: X 33 CrS 16 Mn 0.80 good machinability, high-alloyed AFNOR: Z 35 CD 17.S ≈ 1080 N/mm² 1.2085 Cr 16.00 AISI: ≈ 422+S S 0.06 Ni 0.30 C 0.21 Steel for case-hardening Cavity plates and machine parts DIN: 21 MnCr 5 Si 0.25 alloyed AFNOR: 20 MC 5 ≈ 660 N/mm² 1.2162 Mn 1.25 AISI: 5120 Cr 1.20 C 1.18 Cold-work steel Core pins, punches, small turned parts DIN: 115 CrV 3 Si 0.25 alloyed, wear-resistant AFNOR: 100 C3 Mn 0.30 ≈ 740 N/mm² 1.2210 UNI: 107 CrV 3 KU Cr 0.70 AISI: L2 V 0.10 C 0.40 Tool steel Cavity plates, inserts and DIN: 40 CrMnMo 7 Si 0.40 alloyed and pre-toughened, ideal for nitrid- high-strength machine parts AFNOR: 40 CMD 8 Mn 1.50 ≈ 1080 N/mm² ing and polishing 1.2311 UNI: 35 CrMo 8 KU Cr 1.90 AISI: P20 Mo 0.20 C 0.40 Tool steel Cavity plates for mould bases and die sets Si 0.40 alloyed and pre-toughened, good machi- with increased requirements on strength DIN: 40 CrMnMoS 8-6 Mn 1.50 nability AFNOR: 40 CMD 8.S ≈ 1080 N/mm² 1.2312 Cr 1.90 AISI: P20+S Mo 0.20 S 0.06 DIN: X 38 CrMo 16 Tool steel Moulds for processing corrosive plastics C 0.36 AFNOR: Z 35 CD 17 pre-toughened, corrosion-resistant, Cr 16.00 ≈ 1010 N/mm² 1.2316 UNI: X 38 CrMo 16 KU polishable, high-alloyed Mo 1.20 AISI: ≈ 422 C 0.38 Hot-work steel Cavity plates and inserts for plastic injecti- DIN: X 37 CrMoV 5-1 Si 1.00 high-alloyed on moulds AFNOR: Z 38 CDV 5 Mn 0.40 ≈ 780 N/mm² 1.2343 UNI: X 37 CrMoV 5-1 KU Cr 5.30 AISI: H11 Mo 1.20 V 0.40 C 0.38 Hot-work steel Cavity plates and inserts for die casting (Al, DIN: X 37 CrMoV 5-1 Si 1.00 suitable for mirror polishing, electro-slag Mg, Zn etc.) and injection moulds 1.2343 ESU AFNOR: Z 38 CDV 5 Mn 0.40 remelted, high-alloy ≈ 780 N/mm² UNI: X 37 CrMoV 5-1 KU Cr 5.30 (ESR) AISI: H11 ESR Mo 1.20 V 0.40 C 0.40 Hot-work steel Standard material for hot-work tools, DIN: X 40 CrMoV 5-1 Si 1.00 high-temperature resistant, high tempe- extrusion moulds, dies, tools for plastics AFNOR: Z 40 CDV 5 Cr 5.30 ≈ 780 N/mm² rature wear resistant, excellent
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