Plastic Mold Steel-0511 - Doosan

Doosan Heavy Industries & ConstructionDOOSAN PLASTIC MOLD STEEL

DOOSAN HEAVY INDUSTRIES & CONSTRUCTIONglobal leader in power & waterDoosan has continued to research and develop technology for producing outstandingmold steel, which is now being supplied for the benefit of customers worldwide.Plastic mold steel from Doosan is also accelerating the development of industry.

DOOSAN PLASTIC MOLD STEELContEntSintroduction 04plastic Mold steelsHP1A / HP4A(D1) / HP4MA(D2) 06HigH Quality plastic Mold steelsHP70 / HEMS1A 10pHysical properties 13Manufacturing process 1403

DOOSAN PLASTIC MOLD STEELINTRODUCTIONPolishing Property(Schematic Diagram)HP70HEMS1AHardness >HP1AMirror polishability >HP4A(D1)General ProductsHP4MA(D2)Semi-transparentProductstransparentProductsSuper mirrorfinish Products

DOOSAN HEAVY INDUSTRIES & CONSTRUCTIONDoosan’s Plastic Mold Steel “HP”DooSAn Heavy Industries & Construction Co., Ltd. (DooSAn) has been producing various types of casting& forging products for the many years ranging from power generator, chemical vessel, steel mill, shipbuilding to cement industries.Since being founded, DooSAn has also supplied plastic mold steels and tool steels to the high technologysectors such as electric, electromagnetic, optical, telecommunication industries as well as the fields ofsemiconductors, precision machinery, construction machinery, automobile, etc.DooSAn is very pleased to be given the chance to supply its products to the world. As mentioned above,its products are well known for their excellence in quality. Doosan is proud to inform you that it has patentsfor plastic mold steels in Korea as well as acquired certificate of ISo 9001 (AnSI / ASQC Q91).DooSAn will continuously do its very best in improving the quality of plastic mold steels to its limit. Wewill promise satisfaction to all of our customers.new types of high-quality free-cutting steel for plastic moldings, HP series plastic mold steels, have beendeveloped under a strict quality assurance system with DooSAn’s modern facilities.Compared with the conventional steel materials of other companies, the machining time for our newproducts can be reduced by a maximum of 40%. Because of special alloy elements in our HP series plasticmold steels, one can obtain better etching workability, polishing workability and weldability than in manyother products.As a result, not only is the efficiency of metal mold work improved and the service life of the cutting toolsgreatly extended, but one can also make excellent plastic products. HP steels and HEMS1A are highperformance and high-precision plastic mold steel.Use of our newly developed HP steels and HEMS1A can make a major contribution to the improvementproductivity and rationalization of production.DooSAn’s Plastic Mold SteelsDooSAnBRAnD D/nREFEREnCE SPECIFICAtIonDIn AISI JISASSABSUPPLIEDConDItIonAPPLICAtIonSHp1a1.1210Improved1050ImprovedS55CImproved-Prehardened• General purpose large sizemold baseHp4a(d1)1.2311Improved4140ImprovedSCM44oImproved618ImprovedPrehardened• Core & Cavity• General purpose mold forMass-productionHp4Ma(d2)1.2738ImprovedP20ImprovedSnCMImproved718ImprovedPrehardened• Higher hardness mold• Bumper mold• General purpose mold forMass-productionHp70-P21ImprovedDaido’snAK80-Prehardened• High grade mold base formirror surface & EDMrequirementHeMs1a1.2083Improved420ImprovedSUS420J2ImprovedStAVAXImprovedAnnealed• Corrosion resistant precisionplastic mold• Glass mold & tV brauntube mold05

DOOSAN PLASTIC MOLD STEELHP1A / HP4A(D1) / HP4MA(D2)Material CharacteristicsHp1a• General Purpose for Plastic Molding• outstanding Machinability• Less Residual Stress and DistortionHp4a(d1)• Excellent Machinability• Superior Cleanliness, Weldability andPhoto-etching• Better Hardness DistributionHp4Ma(d2)• Better Machinability• outstanding Hardness Distributionand Wear Resistance• Superior Cleanliness and PhotoetchingManufacturing CharacteristicsMelting• Superior Cleanliness due to HighVacuum Degassing Processforging• no Solidification Defect by Using130Mn & 42Mn PressHeat treatMent• Excellent Mechanical Properties byoptimal Heat treatmentMain Concepts of Developing HP4A(D1) & HP4MA(D2)• Adopting new concept in alloy design to make up for weak points with maintaining strong points• optimizing quality heat treatments to get mechanical properties.Quality Properties■ chemical compositions(Unit :wt%)Material Hp1a Hp4a(d1) Hp4Ma(d2)C >0.50 0.25 ~ 0.35 0.25 ~ 0.35ni

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION■ photo etchingthere is no serious trouble in the most segregated part of 770mm heavy block.Hp4a(d1)Hp4Ma(d2)■ segregationHP4A (D1) and HP4MA (D2) are superior to HP1Ain segregation.Hp1aHp4Ma(d2)■ Mechanical properties graphYieldtensile■ cross sectional Hardness distributionHardness is uniformly distributed throughoutthe cross sectionStrength(n / mm2)1000900800700600500400300200Hardness (HRc)3634323028262422HP4MA (D2)HP4A (D1)100HP1A HP4A (D1) HP4MA (D2)20-200 -100 0 100 200Distance from center(mm)07

DOOSAN PLASTIC MOLD STEELHP1A / HP4A(D1) / HP4MA(D2)■ MachinabilityHP4A(D1) & HP4MA(D2) give 2 timeslonger in life of tool and shorter inmachining time than DIn materials.test condition• Cutter : M415SP-05R-12• V=250m/min f=0.15mm/tooth• Insert : SPKn1203EDtR-HP/ tt7070 • d=2.0mm Center cutting dryVBmax (mm)0.70.60.51.2311Hp4a(d1)VBmax (mm)0.70.60.51.2738Hp4Ma(d2)0.40.30.2life of tool1.6 3.30.40.30.2life of tool1.5 3.20.10.10.001 2 3 4Cutting Distance (mm)0.001 2 3 4Cutting Distance (mm)■ procedures for repair weldingIn case of design change and defects during operation, repair welding has to be performed.Due to high strength of mold steel repair welding requires the extreme care and strict supervision.descriptionHp1arepair welding ManualHp4a(d1)Hp4Ma(d2)remarksFiller MetalsAWSER70S-4ER70S-6AWSER80S-B2ER80S-GAWSER80S-B2ER80S-GER9oS-B3Welding Rod : 1.6ø, 2.4øPreheat temp.250±50℃(200~300)300±50℃(250~350)250±50℃(200~300)Fuel : LnGFuel Pressure : 0.5 kg/cm 2Post Heat treatmentWelding(250~350℃)PreheatingPost HeatingtP30(min) / inch*tP (Holding temperature)HP1A : 270±20℃HP4A(D1) : 350±20℃HP4MA(D2) : 320±20℃PWHtPost-Weld Heattreatment (PWHt)max.100℃/hrWelding(200~350℃)Preheating*(500~600℃)1-2hrSlow cooling(≤50℃/hr)300℃Required Polishing andEtching Workability*Slow cooled using insulating materials.

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION■ weldabilityImproved consistency in hardness before/after PWHt.Hardness (Hv)500450400350300250200150500450400350300250200150weld HaZ baseHp4a(d1). surfaceas weldafter PWHtHp4a(d1). centeras weldafter PWHt02 46 8 10Vickers Hardness (Load:5kg)650600550500450400Hp4Maas weldafter PWHtHp4Ma(d2)as weldafter PWHt350300250200150base HaZ weld HaZ base-25 -20 -15 -10 -5 0 5 10 15 20 25Distance from the center (mm)09

DOOSAN PLASTIC MOLD STEELHP70 / HEMS1ACharacteristicsHp70• Maintain excellent surface finish• Uniform hardness throughout the cross section• Extreme hardness and superior wear resistance• Excellent electric discharge machinabilityHeMs1a• Excellent corrosion resistance• Excellent mirror finishing• High precision• Uniform hardness throughout the cross sectionQuality Properties■ Vacuum-degassing processour free cutting steels are vacuum-degassed and forged.they have 1) excellent cleanliness2) no pin holes3) desegregation of alloy elements.■ chemical compositionsMaterialcchemical composition(wt, %)ni cr Mo special alloysHp70< 0.25> 2.00-< 0.50AddedHeMs1a0.25~ 0.30≤0.3012.00 ~ 12.50≤0.50Added■ Mechanical propertiesMaterialyield strength(kgf/mm 2 )tensile strength(kgf/mm 2 )elongation(%)reduction of area(%)surface Hardness(HRc)Hp70100 ~ 115120 ~ 135> 17> 5237 ~ 41HeMs1a60 ~ 7075 ~ 85> 25> 5023 ~ 52

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION■ cross-sectional Hardness distributionHardness (HRc)504540Hp70Hardness (HRc)71605039HeMs1a(after Q+t)35303026-250 -200 -150 -100 -50 0 50 100 150 200 250Distance from center (mm)050 100 50 0Distance from the surface (mm)■ Machinability■ High temperature tensile propertiesCutting Force (n)800700600500400300• table Moving Speed: 160mm/min.• Face Milling ConditionCutting Speed: 261m/min.Insert type: SPKn1504EDRLubricant: notensile Strength (kgf/mm 2 )120100806040200Hp7020Hp701.0 1.5 2.0Cutting Depth (mm)00 100 200 300 400temperature ( 0 C)■ nitriding characteristics■ electric discharge MachiningHardness (Hv)800 500Hp70450700600500400300520 0 c, 5hr470 0 c, 5hr0 5 10 15 20 25 30 35 40Distance from the surface (10 -2 mm)Hardness (Hv)400350300250200Heat AffectedLayerHp70• EDM Condition: M/C: tron150c: Electrode: Copper(8 ø ): Surface roughness: Ra4μm0 2 4 6 8 10 12 14 16 18 20Distance from the surface (10 -2 mm)11

DOOSAN PLASTIC MOLD STEELHP70 / HEMS1A■ Heat treatmentMaterialHeMs1aQuenching ( 0 C)1000 ~1050oil coolingHeat treatment conditionstempering ( 0 C)100 ~ 500 45 ~ 52550 ~ 700surface Hardness(HRc)23 ~ 33■ cleanlinessCleanliness (%)HEMS1A steel, being treated with vacuum-degassingand ESR process, shows an excellent cleanliness.0.140.120.100.080.06■ corrosion resistanceWeight Loss (△g/g)0.200.150.105% hydrochloric acid0.040.020.0500.00AISI 420HEMS1AAISI 420HEMS1A■ tempering Hardness curveHardness (HRc)656055504540353025asquenchedQuenching temp. : 1025 0 C100HeMs1a200 300 400 500 600tempering temperature( 0 C)■ polishing workabilityFig. shows workability of polishing and finishing.Materialra.(μm)rmax.(μm)remarkHp70HeMs1a0.0190.010.1670.031μm Diamond paste use

DOOSAN HEAVY INDUSTRIES & CONSTRUCTIONPHYSICAL PRoPERtIES■ physical propertiesMaterialtemperature( 0 C)thermalconductivity(W / m·K)specific heat(Cal / g·0C)coefficient ofthermal expansion(10 -6 / 0 C)Room temperature-- -Hp1a10020030040050060050.24248.14844.79941.031--0.1160.1250.1320.138--13.7614.5115.3615.8116.2216.54Hp4a(d1)Room temperature 100100200300400500600-42.28741.86840.19337.263--- -0.1150.1240.1310.137--13.8714.3214.8215.5815.7516.08Hp4Ma(d2)Room temperature 100100200300400500600-40.61240.19339.35637.681--- -0.1170.1260.1350.139--11.8213.2314.1614.6414.8915.14Hp70Room temperature 10010020030040050060033.117633.578132.992031.191728.805226.083822.14820.4990.5130.5440.5970.6440.7280.766-12.8912.4413.3814.0114.1714.56HeMs 1a10020030040025.12126.37727.21428.052-11.611.912.412.713

DOOSAN PLASTIC MOLD STEELMAnUFACtURInG PRoCESSManufacturing Process1. Melting > 2. V.S.D(Ingot Making byVacuum Steam Degassing) >3. E.S.R >4. Heating > 5. Forging > 6. Heat treatment > 7. InspectionMeltingrefiningingot Making inVacuum conditionHeatingforgingpreliminary HeattreatmentMachiningVacuumdegassingingot Makinge.s.rshipmentinspectionQuality Heat treatment

Doosan Heavy Industries & Constructionwww.doosanheavy.comSeoul offICeHeaD offICe anD CHangwon plant465 Gangnam-daero, Seocho-Gu, Seoul 22 DoosanVolvo-ro, Seongsan-Gu137-920 Korea Changwon, Gyeongnam 642-792 Koreatel. 82-2-513-6114 Fax. 82-2-513-6200 tel. 82-55-278-6114, 7114 Fax. 82-55-264-5551,5552