Zapp Materials engineering Tool Alloys - Metaling

1 zapp Materials engineeringTool Alloys0506081012141516 COntentse XClUsi Ve pr aCti Cal eXperienCeasp 2000 steels CpM steelsMain adVantages Of tHe p OWder Me tallUrg iCal HigH perfOrManCe steelstOOl steelsserViCes and speCial faCilitieslOgistiCs and QUalitYlist Of addressesExclusivE practical Exp Eri Enc E with convEntional and powdEr mE tallurgical stEEls04 05 zapp Materials engineering tool AlloysIn modern tool engineering , there are two possible Materials from which highly stressed tools can be made conventional tool steels or powder metal-lurgical high performance (PM) Materials . Which is the most economical, and when?a baCkgrOUnd Of 25 YearsAs the distributor for the world s leading manu-facturers of PM products, we also have acquired comprehensive practical experience of these products.

2 As a result, we are able to make precise statements as to the price/performance ratio of the two types of steel. To this must be added our exhaustive knowledge of their applications and our ability to make logical recommendations, not only about the Materials themselves but also about heat treatment and spark erosion processing. In combination, the final effect will lead to an increase in your MetallUrgiCal Materials tHe OptiMUM in steel teCHnOlOgYAt first sight, admittedly, the high cost production method employed makes PM Materials relatively expensive. In return, however, they satisfy the most exacting requirements. Moreover, they appreciably improve machine utilization. If you are now wondering whether these advantages apply in your particular case, simply call us, send us an e-mail or write to us.

3 We will analyze the problem, indicate alternative solutions and advise you Ce Makes perfeCt prOdUCtsOur practical experience, however, not only helps our customers throughout the world. It also serves as a constant driving force behind the product development work of our a neW teCHnOlOgiCal generatiOnEven today, we are intensively occupied with the future activities of countless industries. Thus, a new generation of plastics is creating a demand for new technologies in their processing. These, in turn, call for tool Alloys which are a match for the new challenges. Other sectors in which technolo-gical advances are constantly being made are the automotive industry, the food industry and the sinter press and metalworking industries. We should be seen as a premium resource, capable of finding new answers to new a premium supplier.

4 Founded in 1701 by Hermann zapp in R nderoth, Germany. Today, the zapp Group has commitments worldwide with production sites and service centers. Its core activities lie in the manufacture of ready- to-use fabricated products made of high performance Materials for demanding applications. The zapp Group is composed of three divisions: Precision Wire, Precision Strip, and Materials engineering for specialty Materials and tool Alloys . Our objective is to ensure that every customer has a competitive advantage as a result of close mutual 2000 stEElsasp 2000: esH-dValintM prOCessThe ASP process is a powder metallurgical tech-nique, comprising hot isostatic pressing of rapidly solidified gas atomised powder. A material of homogeneous distribution of the components of the steel is obtained.

5 During gas atomization, the melt is disintegrated by powerful jets of nitrogen gas into small droplets. The powder is collected in a steel capsule which is subsequently evacuated and welded. 1. graphite electrodes for heating and temperature regulation 2. slag cover 3. Molten steel 4. n2 gas 5. Atomizing of molten steel with nitrogen gas 6. encapsulation of powder in steel cylinder 7. Welding of cylinder after vacuum evacuation 8. Hot isostatic pressing 9. Hot forging 10. Hot rolling12567891043asp prOCessanalYsEs and prop Erti Es Chemical composition (standard values in %) .1 7..13 . prOperties Of asp 2000 Materials 9080706050403020100asp 20 5 3 64 Hrcasp 2 0 0 5 62 Hrcasp 2 0 2 3 62 62 Hrc1.

6 2 3 7 9/D 2 62 Hrcn steel gradeasp 2005asp 2012asp 2023asp 2030asp 2040asp 2053asp 2060 After hot isostatic pressing of the ASP-powder the microstructure of this material is fully homog-eneous and the mechanical properties are isotro-pic. Bars, wire rods, strip and sheets are obtained after forging and rolling. Wear resistance i mpact toughness06 07 zapp Materials engineering tool Alloys Asp and TM DVAlin are registered trademarks of erasteel, France (paris).08 09 zapp Materials engineering tool Alloyscpm stEElsanalYsEs and prop Erti Es Chemical composition (standard values in %) . prOperties Of CpM Materials 62 62 HrcCpM rex M4 62 HrcCpM 3 V 58 HrcCpM 1 0 V 63 Hrcsteel gradeCpM 1 VCpM 3 VCpM 9 VCpM 10 VCpM 15 VCpM 420 VCpM s 30 VCpM r ex M4 CpM r ex t15 CpM r ex 76 CpM r ex 121 CpM prOCessIn its approach to the CPM processing technique, Crucible has concentrated, among other things, on the production of high alloyed cold-worked steels.

7 These innovative powder metallurgical Alloys , which are particularly rich in vanadium, have largely been patented; they fulfill the highest performance Atomization2. powder3. screening4. Filling5. Capsulation 6. Hot isostatic pressing7. Hot forging8. Hot rolling 12345678 CpM prOCess CpM is a registered trademark of Crucible, (syracuse, ny). Wear resistance i mpact toughnessmain advantagEs of th E powd Er mE tallurgical high pE rformancE stE ElsadVantages1. allOYsThe highest alloy levels can be achieved without any adverse effect on mechanical tOUgHnessThe uniform distribution of carbides and absence of metallurgical defects increase security against fracture and fatigue Wear resistanCeThe volume and hardness of the carbides increase resistance to abrasive and adhesive grindabilitYMachining ability is improved as a result of the small globular diMensiOnal stabilitYPowder metallurgical steels are free of segrega-tions.

8 This leads to substantially improved dimensional stability. Tools need less CleannessExcellent polishing and EDM machining capabili-ties result from the highest possible degree of purity, known as Ultra Clean .p M -H i gH p e r fO r M a nC e steelpositive effects of the uni-form microstructure for best cutting edge O n V e n t iO n a l H i gH speed steelCarbide clusters near the cut-ting edge produce micro- and macro-chipping. 10 11 zapp Materials engineering tool AlloystYpiCal appliCatiOnseCOnOMY CalCUlatiOn toolMachineproduction material Value of production run steel gradeMaterial costsTotal tool costsMaterial cost proportionQuantities per regrindnumber of regrindsCosts per regrindMax. number of parts per toolTwo further tools requiredAdditional regrinding costs (30 x 150) Costs of production rundiestamping pressst 37 thickness 80 15000015 150approx.

9 2250000 8000 4500 18750 CpM 10 V 360 42808 . 41 %approx. 50000015 1508000000 0 0 6530 it must be admitted that, at first sight, powder metallurgical high performance Materials are relatively expensive. But often only at first sight. A detailed price/performance compa r-ison between powder metallurgical and con-ventional tool steels often produces some surprising example of a cost-effectiveness study has revealed a saving of eUr 12220 by the use of CpM 10V materialCu-Be, s = mm iron powder D 7 Density kg/dm3st 52, s = 8 mm 550 Mpast 2k, s = mm 500 Mpairon powder Density kg/dm3 Qste 460 TM, s = mm 800 Mpa16 MnCr 5, s = mm 550 Mpasteel CpM 10 pM CpM 10 CpM r ex CpM 3V 1. 2767 pM CpM + TiCn Asp 2053 Asp 2005 Hardness [Hrc]61 6264 6358 5959 5953 61 5561 6160 60performance75000 parts per regrind 1500000 parts per regrind54000 parts 75000 parts20000 parts per regrind 60000 parts per regrind25000 parts per regrind 300000 parts per regrind5000 parts 10000 parts 310000 parts150000 parts per regrind 500000 parts per regrind80000 parts per regrind 190000 parts per regrindtype of toolpunch sinter pressing punch (calibration)Fineblanking Forming punch sinter pressing tool punching tool Fineblanking pOWder MetallUrgiCal MiCrOstrUCtUreCOnVentiOnal MiCrOstrUCtUre Chemical composition (standard values in %)

10 COld WOrking zapp -brand nameC 120lVC 50lC 120 sWC 120sCW 20 HlCn extralCn 45VM 20din en is O 4957X210Cr12 X153 C r M oV12X210 CrW1260 WCrV855niCrMoV745niCrMo1690 MnCrV8C 2 . V .10 0 .10W ni Co material no. din Chemical composition (standard values in %) HOt WOrking zapp -brand nameCVl 10 CVl 10 VCVl 30lC 50din en is O 4957X37 CrMoV5 -1X4 0 CrMoV5 -1 C ni Co material no. din nameC 135 MMCl 3 MCl slC 160 MCl 4K 90 lK 35 ln 35din en is O 4957 X 3 8 C r M o16 Chemical composition (standard values in %) plastiC MOUlding material no. din . 2 3111. 23121.. 41121. 412 0 0 W ni + s + AlMn namessVB 50ssB 120sslB 50ssWl 50din en is O 4957 Hs 10-4-3-10Hs 6-5-2-5Hs 6-5-2CC Co Chemical composition (standard values in %) HigH speed steels material no.