40HRC Pre-hardened High mirror polish Plastic injection ...€¦ · Plastic injection mold steel...

40HRC Pre-hardened

High mirror polish

Plastic injection mold steel

NAK80

40HRC Pre-hardened

High mirror polish

Plastic injection mold Steel

NAK80

Daido Steel Co., Ltd.

Contents

1. Daido Steel: Company profile

2. Shibukawa Plant: Tool steel mother plant

3. High quality mold steel production

4. Features of NAK80

5. Application of plastic mold steels

Daido Steel: Company profile

Daido Steel: Company profile

• Name : Daido Steel Co.,Ltd.

• Incorporated : Feb. 1，1950

（Founded） : Aug.19，1916

• Capital : 37.2 billion yen

• Annual Sales : 472 Billion yen (2011)

• Number of employees : 3,378

Historical Landmark 1.5t Heroult Furnace

The oldest electric arc furnace in Japan as industrial basis.

Now it has become the

Daido’s company

treasure.

Certified as Historical

Landmark by ASM in

1988.

DAIDO STEEL

Company Profile

Tokyo Head office

Head Office

(Nagoya)

Fukuoka Sales Office

Osaka Branch

Chita Plant

Hoshizaki

Plant

Shibukawa plant

Daido Steel Daido Steel Locations

Specialty steels 60%

Electronic and Magnetic Materials

9%

Parts foｒ Automobile &

Industrial Equipments

22%

Engineering 5%

New Materials 2%

Trading & Service

2%

Sales by business segment

Domestic demand of tool steels

Carbon steels Low

alloy

Cold work die

Hot work die

Forging die

Plastic

High speed

10,700 t/ Month (Apr.–Sep., 2011)

Shanghai Nikka Metal Products Co.,Ltd.

Daido PDM (Thailand) Co.,Ltd.

Daido Steel Co.,Ltd.

Pt. Astra Daido Steel Indonesia

Foshan Summit Nikka Mold & Metal Products

Co.,Ltd.

Daido Tienwen Steel

(Guangzhou) Co.,Ltd.

Daido Amistar (M) SDN BHD

Daido Amistar (S) PTE Ltd.

Daido Steel (Shanghai) Co.,Ltd.

Daido’s Tool Steels: East Asia Network

Daido Teinwen Steel Co.,Ltd

Daido Steel Co.,Ltd.

(Bangkok Representative Office)

Daido Amistar (Vietnam) Co.,Ltd.

Lung Kee Metal Ltd.

Ming Lee Steel Mould Products Co.,Ltd.

Wonil Special Steel Co.,Ldt.

YDP Steel Co.,Ltd.

Shanghai Nikka Metal Products Co.,Ltd (Dalian Office)

Daido Steel (Shanghai) Co.,Ltd.

Guangchou Branch

Daido Steel (America) Inc.

(Chicago, IL)

International Mold Steel

(Florence, KY)

Shibukawa plant： Tool Steels mother plant

Free forging products by Shibukawa plant

Shaft 7%

Other 15%

Aircraft

Power Generation

Ship building

Valve 24%

Other 1%

Disc 5%

Spindle bolts, etc. 10%

Steel Making 4%

Other 34%

Glass roll

Drill collar Jet engine

bearing

Engine

valve

Impeller Compressor disc

Continuous caster

pinch roll

Jet engine

shaft

Shibukawa Plant:

Producing highly reliable

aircraft engine parts

Approval list of civil aircraft engine shafts

BUILDER TYPE NAME OF PARTS MATERIAL

P&W

PW4056 Coupling LPT Shaft Ti-6Al-4V

PW4168 Coupling LPT Shaft Ti-6Al-4V

PW4088 Coupling LPT Shaft Ti-6Al-4V

PW4098 Coupling LPT Shaft Ti-6Al-4V

PW2037 Shaft LPC 17-22A

PW4056 Shaft Front 17-22A

JT9D Shaft Front 17-22A

JAEC V2500 Shaft LP 3Cr-1Mo-0.2V

Shaft Stub 3Cr-1Mo-0.2V

GE GE90 Mid Fan Shaft MA250

CF34-8C Shaft Fan Drive Inconel 718

R/R TRENT800 Shaft LPT 3Cr-1Mo-0.2V

Shaft stub

Shaft LP

High quality mold steels

produced by Shibukawa plant

Melting

Remelting

Forging

High quality mold steel production

Forgings made by

Shibukawa plant

High quality mold steel production

Electric Arc Furnace melting

High quality mold steel production

Vacuum Ladle Refining

High quality mold steel production

Casting

Electric Arc Furnace

Clean steel melting

Ingot Casting (2.2 –32.5t)

Ladle Furnace (Vacuum)

･Precise control of chemistry and casting temperature

･Refining by slag

Remelting Equipment

VAR（Vacuum Arc Remelting） ESR （Electro Slag Remelting）

Electro Slag Remelting furnace

■ Progressive melting with resisting heat

by direct electricity

■ Refining by specially blended slag

■ Clean steel with less non metallic inclusions

■ Homogenized and fine macro and micro

structure in radial and longitudinal directions

■ Better surface than that of VAR

Electrode traveling device

Water cool

mold

Melting by

resisting heat

Mother ingot

(Electrode)

Vacuum Arc Remelting furnace

■ Progressive arc melting and

solidification in evacuated chamber

■ Reduction of gas content

■ Clean steel with less non metallic inclusions

■ Homogenized and fine macro and micro

structure in radial and longitudinal directions

Mother

ingot

(Electrode)

Water cool

mold

Evacuated

Chamber

Evacuating

duct

Melting by arc

High quality mold steel production

Electro Slag Remelting (Vacuum)

High quality mold steel production

Vacuum Arc Remelting

7,000 ton Forging Press (Since 2008.4)

How fast the new machine works.

7,000 t 3,500 t

・Grade：304N2， Heating temp.：1200 degree C

・Size：750 FE x 1700 H → 800 H

Free forging in the world

Max.Ingot Weight (t）

0

2000

4000

6000

8000

10000

12000

14000

1 10 100 1000

Max

.Fo

rgin

g lo

ad

(t)

★

Japan Steel

Works

JCFC Mitsubishi

Metal

Kobe

Hitachi

Daido

Cartech (US)

Boehler(Austria)

Saar Shmiede (Germany)

FOMAS (Italy)

Koshuha

Taiheiyo

Tool Steels, Stainless steels High alloys

Low alloys Large sized

Available section of forged block

Thick (mm) 136 - 550

Width (mm） 200 - 1200

170 - 550 D

Rolling

Wire rod mill

Large size bar mill

Small size precision bar mill

Available section of rolled bars Thick (mm) 16-90 91-105 106-135

Width (mm） 110-140 110-310 205-410

10 - 162 D

E-quality

rolled flat bar

1. Thickness tolerance

2．Width tolerance

3. Convex and square-ness

4. Straightness, Bending

１．Thickness Tolerance

Conventional

Ａ +0～+α

（Ａ：Nominal size）

Ａ +0～+1.5mm Ａ +0～+0.5mm

2. Width Tolerance

Ｂ +O～+β

（Ｂ：Nominal size）

Ｂ +0 ～ +3～4mm Ｂ +0 ～ +2～3mm

Conventional

3. Convex & Square-ness

Convex and square-

ness

0.5～1.5mm／side

Large convex on sides

≦1.0mm／side

Slight concave on sides

Conventional

Features of NAK80

Plastic injection mold steels: Classification and chemistry

Classification Daido AISI Hardness Chemistries(%)

brand (HRC) C Ni Cr Mo V Other

SC PXZ 1055 (30HS) Low C－Mn steel S

SCM PDS3 4140 26～30 0.45 － 1.1 0.25 － －

PX5 P20 30～33 0.2 － 2 0.5 － S

SUS G-STAR 420F 33～37 0.35 － 16 1 － S

P.H. NAK55 P21-Mod. 37～43 0.15 3.0 － 0.3 － Cu,Al，S

NAK80 37～43 0.15 3.0 － 0.3 － Cu,Al

SKD DH2F H13-Mod. 38～42 0.37 － 5.3 1.3 1 S

P.H. NAK101 630-Mod. 30～35 17Cr-4Ni －

SKD DHA1 H13 45～50 0.39 － 5 1.3 1 －

DC53 D2-Mod. 60～62 0.9 － 8 2 0.3 －

PD613 D2-Mod. 56～61 8Cr－1Mo －

SUS S-STAR 420-Mod. 50～53 0.38 － 13.5 0.1 0.3

Maraging MAS1C － 50～53 ≦ .03 18.5 － 5 － Al,Ti,Co

Pre

-har

den

ed s

teel

H

T s

teel

HT：Hardened & tempered, P.H.：Precipitation hardening

Plastic injection mold steels

Classi-

fication

Hardness

(HRC)JIS AISI Aichi

JFE

SteelKobe Sanyo

13 SC 1055 AUK1 JFE-MD1

KTSM21

KTSM2A

KTSM22

PC55

28 SCM 4140 AUK11JFE-MD3

JFE-MD5KTSM31

SCM-M P20 KTSM3M PCM30

Pre-hardened

steel 33SUS 420

SUS

(F/M)

35 SUS S17400 QHS6

SKD61-M H13

P21PCM40

PCM40S

P21＊

60 SKD11-M D2 QCM8

Hardened &

tempered57

SUS440C

-M440C

QPD5

SPC5

(P/M)

52

Age hardening

steel≧50 Maraging

Other

40Non

-Mnagnetic

＊Stain resistance

40Other

Sumitomo Daido Kosyuha Hitachi Fujikoshi Uddeholm Boehler

SD17

SD18T

KPM1

KPMAX

SD61 PDS3

SD70

SD100PX5 KPM30 HPM7

PLAMAX

IMPAXHH

M200

M201

M238

S-STAR

D-STAR420M HPM38 STAVAX

M303

M310

G-STAR HPM77RAMAX-2

RoyAlloyM315

NAK101 U630 PSL CORRAX N700

DH2F KAP90F FDAC

NAK55

NAK80

KAP65

KAP88

HPM1

HPM-PRO

M261

M461

CENA1

HPM-MAGIC NIMAX

PD613 KD21 HPM31

RIGOR

SLEIPNER

CALDIE

CALMAX

K105

K110

K340

SUS440C SUS440C 440CUNIMAX

ELMAX

M340, M390

N685, N690

N695

S-STAR

D-STAR

G-STAR

HPM38

HPM38S

HPM7

STAVAX

POLMAX

MIRRAX

MAS1C KMS18-20 YAG NAG21

ASL407 CORRAX

NMS1 HPM75

NAK80: Features

Main chemistry：0.1C- 3Ni- 1Al- 1Cu

Strengthening by precipitation hardening

40HRC pre-hardened steel

Shorter mold making time

Features of low C-Ni-Al-Cu precipitation hardening steel

1. Wear resistance

2. High machinability

3. Small distortion

4. Easy repair welding

5. Easy ED machining

6. High thermal conductivity

Ni-Al-Cu Precipitation

hardening steel

NAK80：0.1C-3Ni-1Cu-1Al

37-43 HRC Pre-hardened

steel

Super clean steel

by double melting Reliable

quality

1. Superb mirror polishing 2. Fine ED machined surface 3. Superb textured surface

Advantage of pre-hardened steel

Hardened and tempered steel

Steel Rough

machining Heat

treating Straightening Finishing

Steel Rough and finish

machining

Time saving

Pre-Hardened Steel

Heat treated by mill maker

Pre-hardened steel

Shorter delivery time

due to heat treatment free

Inter-metallic compounds

Solution Treatment

Aging

As ST Aging temp.→

H

ard

nes

s →

30HRC

40 HRC

Heat treatment Hardness

＜Solution treated＞ ＜Aged＞

Matrix：Bainite

Ni3Al, Ni3Cu precipitates

The principle of precipitation hardening

Fine precipitates strengthening

to 40HRC

0.2 μm

NAK55（Arrows show MnS） NAK80

Optical micrographs of NAK steels

25μｍ

Arrows indicate MnS (Manganese sulfide).

NAK80: Supporting plastic

injection molding

40HRC pre-hardened steel

Shorter mold making time

Easy machining

Cost reduction

Easy machining in spite of 40HRC Relative comparison: Endmilling

Mac

hin

abili

ty i

nd

ex *

* Machinability NAK55：100

P20 PX5

* Machinability NAK55：100

Mac

hin

abili

ty i

nd

ex *

P20 PX5

Easy machining in spite of 40HRC Relative comparison: Drilling

Recommended machining conditions

Drilling

High speed steel drill (Coated)

Drill dia. (mm)

Cutting speed (m/min.)

Feed (mm/rev.)

Depth of hole (mm)

Step (mm)

0.5 - 32 10 0.01D - 0.02D - 5D D

Carbide drill (Coated)

Drill dia. (mm)

Cutting speed (m/min.)

Feed (mm/rev.)

Depth of hole (mm)

Step (mm)

0.1- 3 3 - 25

40 - 50 30

0.02D - 0.03D 0.1 - 0.2

- 5D - 8D

0.1D - 0.5D D

Recommended machining conditions

Endmilling

Rough machining (Coated carbide)

Tool Size (mm)

Cutting speed (mm/min.)

Feed (mm/tooth)

Depth of cut ap (mm) ae (mm)

Radius EM D12-D63xR4-R8 120 0.1 - 0.6 - R 0.6D - 0.8D Square EM D25 - D63 80 0.07-0.15 - 5 D

Finish machining (Coated carbide)

Tool

Size (mm)

Cutting speed

(mm/min.)

Feed (mm/tooth)

Depth of cut ap (mm)

Depth of cut ae (mm)

Solid ball EM

R0.5 -R 1.5 250 0.05 - 0.1 - 0.1 R -0.2R R2 - R6 250 0.1-0.15 - 0.1R -0.2R

Radius EM

D1-D3xR0.05-R5 100 0.005-0.02 0.01-0.1 -0.2R D4-D12xR0.1-R5 150 0.01-0.1 - 0.5 -0.4R

NAK80: Supporting plastic

injection molding

40HRC pre-hardened steel

Shorter mold making time

Easy machining

Cost reduction

Double melted clean steel

High mirror polishing

Mirror finish grade by machine lapping (#)

60

50

40

20

30

10

0

Har

dn

ess(

HR

C)

G-STAR S-STAR

DC53 PD613

MAS1-C

S-STAR

Pre-hardened steels

Hardened and tempered steels

NAK55

General-purpose miscellaneous goods

Design goods

Semi transparent

Transparent goods

Ultra high

mirror finish goods

NAK80

D-STAR

PX4

0 5000 10000 15000

G-STAR

Mirror polishing of NAK80

High mirror polishing of NAK80

#1200 1800 3000 8000 14000

Machining

EDM

Grindding

Buff polishing

#220 320 400 600

#400 600 800 1000 1200 1500

15μｍ 9 6 3 1

NAK80 ・Polishing too long causes dig out of

the surface

・The shorter the better for buff polishing.

Erase former polishing trace s by

polishing perpendicular to former

direction

Paper polishing

Polishing procedures of NAK80

NAK80: Supporting plastic

injection molding

40HRC pre-hardened steel

Shorter mold making time

Easy machining

Cost reduction

Double melted clean steel

High mirror polishing

Low carbon precipitation hardening steel

Easy repair welding

Repair welding method

Preparation

・ Free from rust, scale residue or any other potential contamination

・Cracks and surface treated layer should be completely removed.

・Remove sufficient stock to repair the crack and insure only sound

materials remains.

・Dress the corners where stock was removed to eliminate any

square corners by rounding to a minimum radius of 3mm.

Welding rod (Filler)

NAK-W

Pre-heating

・ 300 to 400ºC. Heat the mold carefully and gradually.

・Gradual heating in a furnace is recommended. If not, oxygen-

propane or natural gas burner is available.

Welding : TIG

・ DC normal polarity, backward welding

Rod diameter Electrode diameter Current Argon

1.2 1.2 40-70A 4-7L/min.

1.6 1.6 70-150A 6-9L/min.

2.4 2.4 150-250A 7-10L/min.

Post-heating ・ 450 – 500ºC for 1h

Repair welding method

Repair welding characteristics of precipitation hardening steel

As welded Aged after welding

（500℃×5hr）

Welded portion

Even ground and textured surface

across welded portion

Welded portion

Build-up welding properties H

ard

nes

s(H

V)

6 4 2 0 2 4 100

200

300

400

500

Distance (mm)

Base metal Deposited steel

Aged at 500℃

for 5hr

As welded Affected zone

<Welding conditions>

Method ：TIG

Preheating：

300 to 400℃

Current ：

150 to 170A

Welding rod：NAK55W

Hardness comes back to the initial hardness

by post heating after welding

EDM abnormality

As ED

Machined

EDM ＋ ECM

EDM ＋ Polishing

EDM ＋ Shot blast

×100 ×400

Surface abnormality

Har

dn

ess

(HV

)

Distance from the surface (mm)

Heat affected

layer <EDM conditions>

Electrode：Cu

Voltage ：100V

Current ：4.5 A

No affected layer in EDM No hardened layer due to low carbon, 0.1%

300

400

500

600

700

800

0 0.5 1 1.5 2

Distance from the surface (mm)

Vic

kers

har

dn

ess

(HV

)

Ferritic Nitrocarburizing

520℃ x 5 Hr

Nitriding An example of hardness distribution

From automobiles

to daily necessities

Plastic products for our daily necessities

Plastic products for office printer

Panel，PC

Panel，PC

Panel，PMMA

Panel，PMMA

Plastic products for air conditioner

Panel，PS

Plastic products for game machine

PC

PC PC

ABS

Pre-forming & Blow forming of PET bottle

Holder( G-STAR) (NAK80+Plating, S-STAR)

Cavity: Belly Capsule

(NAK80+Plating, S-Star)

Holder

Belly

( Al )

Elongation bar

Bottom

Capsule

Pre-forming

Blow forming

Core

Application of plastic mold steels JIS Daido AISI Hardness Applications

Brand (HRC) Main use Examples of products

SC － 1055 (30HS)･General use for large molds

･Textured molds

・Bumper・Radiator grill・Instrumental panel

・Console box・Convenience goods

・Home appliances・Toys

SCM PDS3 4140 26～30 ･General use for large molds ・Tail light・Mirror cover・Bumper・Radiator grill

PX5 P20 30～33 ・TV cabinet・Lap top ・Sellular phone

SUS G-STAR 420F 33～37 ･Corrosion resisting mold －

P/H NAK55 P21-M 37～43 ･Precision long run mold・Key board・Video camera・Digital camera

・Cellular phone

NAK80 37～43･Precision long run mold

･Mirror polish mold

・Flat TV・Cellular phone・Audio-visual aids

・Transparency cover・Front light

SKD DH2F H13-M 38～42 ･Wear resisting mold ・Core pin

P/H NAK101 630 M 30～35 ･Corrosion resisting mold ・Trough・Earthen pipe

SKD DHA1 H13 45～50 ･Wear resisting mold ・General engineering plastic products

DC53 D2 M 60～62

PD613 D2 M 56～61･Precision, long run mold

･Wear resisting mold・Micro-switch・Connector・Gear

SUS S-STAR 420 M 50～53

･Precision,long run mold

･Mirror polishing,

・Corrosion resisting mold

・Camera,Digital camera・CD lens・Optical lens

・Watch cover

Maraging MAS1C － 50～53 ･High tough pin ・Small diameter pin

Pre

-hard

ned

ste

els

H &

T

Thermo- setting

Thermo- plastics

General use

Fiber reinforced

General use

Engineering plastics

Flame retard

Poly vinyl chloride

Fiber reinforced

Phenol, Melanin,

Epoxy, Polyester

ditto resin -reinforced by CF, GF or metal

Polyethylene , Polypropylene

Nylon, Polyester

Polycarbonate

Flame retarding

FTFE, PVC

Corrosive gas

ditto resin -reinforced by CF,GF or metal

Resin and features Main products

Ash tray, dish,

Convenience goods

Wiring

Auto-body, Chair

Sheet & Film

Bumper, Radiator grill

Instrumental panel

Radio, OA, Cell phone

Machine parts: Gear, cam

Lens

Camera body, Keybord

TV cabinet

Electrical appliance

Pipe, Spout, Sheet, Film

Selection of plastic mold steels by resin

Selection of plastic mold steels by resin

Thermo- setting

Thermo- plastics

General use

Fiber reinforced

General use

Engineering plastics

Flame retard

Poly vinyl chloride

Fiber reinforced

Resin and features Mold steels

Wear resistance

High wear resistance

Pre-hardened steel

High strength & high precision

High wear resistance

Corrosion resistance

Corrosion resistance

PX5,NAK55,80 PD613 PD613 DC53

DH2F,PD613 Coating DC53 DEX20,40

PX5,NAK55,80 Coating DH2F

NAK55,80 PD613 DH2F, DHA1 DC53 PD613,DC53 DEX20,40

S-STAR S- STAR NAK101 Coating

PX5,NAK55,80 PD613 DH2F S-STAR

S-STAR S- STAR NAK101 Coating

1 million

Plastic injection mold steels: Comparison of properties

Mir

ror

po

lish

Wea

r re

sist

ance

HT：Hardened & tempered, P.H.：Precipitation hardening

Number: Better 5, 1 Worse

Properties

SC PXZ 1055 5＋＋ 3 4 5+ 1 5 － 2

SCM PDS3 4140 4 4 4 4 3 4 － 3

PX5 P20 5 5 5 5+ 3 5 － 3

SUS G-STAR 420F 4 3 4 4 3 4 － 4

P.H. NAK55 P21-Mod. 5+ 5 4 3 3 1 － 3

NAK80 3 5+ 5+ 3 3 1 － 3

SKD DH2F H13-Mod. 4 3 3 3 4 3 － 3

P.H. NAK101 630-Mod. 2 4 4 4 3 5 － 5+

SKD DHA1 H13 4 4 4 3 4 4 4 3

DC53 D2-Mod. 4 5 4 2 5 2 3 4

PD613 D2-Mod. 4 5 4 2 5 3 3 4

SUS S-STAR 420-Mod. 3 5+ 5 3 5 3 4 5

Maraging MAS1C － 3 5+ 5+ 5+ 4 5+ 5 3

Pre

-har

den

ed s

teel

H

T s

teel

Classifi-

cation

Daido

brand

AISI

grade

Mac

hia

nb

ility

Text

ure

Wel

dab

ility

Tou

gh

nes

s

Dim

ensi

on

st

abili

ty

Co

rro

sio

n

resi

stan

ce

Mir

ror

Po

lish

jng

Wea

r res

ista

nce

Physical and mechanical properties of plastic mold steels

Physical properties Mechanical properteis

Daido

brand

Hardness

(HRC)

Density

g/cm3

Young's

modulus

Mpa

Thermal

expansion

×10-6/℃

20 to 200℃

Thermal

conductivity

W/MK

0.2%

Yield

strength

Mpa

Tensile

strength

MPa

E

%

Charpy

impact

value

J/cm2

PXZ 26～35HS 7.85 207000 13.1 43.1 490 760 25 50～70

PDS3 26～30 7.85 206800 12.0 43.5 745 890 23 40～60

PX5 30～33 7.85 207300 12.7 42.3 911 1030 20 60～90

G-STAR 33～37 7.80 199900 11.0 25.1 1030

NAK55 37～43 7.80 200900 12.5 41.8 1010 1250 15 18

NAK80 37～43 7.80 200900 12.5 41.8 1010 1250 15 22

DH2F 38～42 7.75 205800 10.8 25.5 1130 1320 10 40

NAK101 30～35 7.80 200900 11.1 25.1 970 1100 10 80

DHA1 45～50 7.75 205800 10.3 26.8 1270 1420 9 40

DC53 60～62 7.87 212700 12.0 23.9 － － － 30**

PD613 56～61 7.80 212700 11.7 26.3 1810 2250 2 45**

S-STAR 50～53 7.80 214500 11.1 23.9 1540 1940 9 25

* MAS1C 50～53 8.02 182300 10.1 28.8 1910 2170 10 50

*Maraging steel Charpy impact value: 2mm U notch, ** 10mm Notch

Pre

-hard

en

ed

ste

el

H &

T

Cla

ss

ific

ati

on