Mold Material

By Franz Russ, Silvia Zinner, Jochen Perko and Patricia Miller

To prevent the negative effects of microstructural inhomogenities in some tool steelsuch as on machinability, polishability, corrosion resistance and mechanical propertiesa new alloy has been created with a more homogeneous microstructure.

Injection mold for fittings made with the N-alloyed prehard stainless.

P
Table 1 Steel

rehardened 400 series stainless steel (DIN 1.2316) is generally used for calibration tools and mold inserts for the plastic processing industry. Today, plastic products are manufactured by mass production, using thermoplastic and duroplastic bulk materials, which are processed by injection molding, blow molding and extrusion molding. The consumption of plastics has influenced the tool steel market, with a demand for more specialized type of tool steels1,5. Increasing ingot sizes can lead to microstructural inhomogenitiessuch as carbide segregation and the appearance of -ferritewhich have a negative influence on the properties of the typical prehardened stainless steel. Such an inhomogeneous structure is shown in Figure 1a. Experience has shown that such microstructural inhomogenities have a detrimental effect on properties such as the machinability, polishabil-

The new plastic mold steel is typically supplied in the hardened-and-tempered condition at approximately 290 to 330 HB, corresponding to about 32 HRc. In this way, a good combination of machinability, hardness and wear resistance is given.
S (wt.%) max 0.030 max 0.005 Cr (wt.%) 15.00 17.00 14.30 14.60 Mo (wt.%) 1.00 1.30 0.90 1.00 Ni (wt.%) max 1.00 0.80 0.90 +
Table courtesy of Bohler-Uddeholm.

C (wt.%) 0.33 0.43 0.25 0.30

Si (wt.%) max 1.00 0.20 0.30

Mn (wt.%) max 1.00 0.60 0.70

P (wt.%) max 0.030 max 0.030

1.2316 N-alloyed prehard stainless

Nominal chemical compositions of X36CrMo17 and the N-alloyed prehard stainless.

28 MoldMaking Technology | May 2009

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Photo courtesy of Bohler-Uddeholm.

A Unique Prehardened Stainless Mold Steel Optimized by Nitrogen Alloying

Figure 1a

Figure 1b

Comparison of the carbide segregation and presence of delta ferrite (1a) in a prehardened 400 series stainless, versus the uniform microstructure (1b) of the nitrogen alloyed prehard stainless.

ity and corrosion resistance. Furthermore, there also is a negative influence on the mechanical properties of the material. To prevent these negative effects, a new alloy (Bohler M303 Extra) has been created with a more homogeneous microstructure, and with better mechanical properties as well as better polishability and machinability.

Experimental New Alloying Concept

Based on the chemical composition of DIN number 1.2316, ThermoCalc calculations were carried out to clarify the occurrence of the ferrite phase. It has been found that at 16 weight percent of chromium,

Figure 2

N-alloyed prehard stainless

DIN 50021 salt spray test: comparison of X36CrMo17 (1.2316) and the N-alloyed prehard stainless.

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MoldMaking Technology | May 2009 29

Figures courtesy of Bohler-Uddeholm.

The N-alloyed prehard stainless has an improved thermal conductivity. This improvement primarily results from the chemical analysis and the very homogeneous microstructure.
a delta ferrite phase occurs at forging temperatures up to 1200C. This effect could be increased by chromium segregation. To reduce the effect of delta ferrite, nitrogen is one of the alloying elements that can be added6. This result was therefore used in the new alloying concept2,3,4. The partial substitution of carbon by nitrogen reduces the amount of chromium rich M23C6-carbides2. As a consequence, the chromium content of the alloy can be reduced without lowering the chromium content of the matrix at typical hardening temperatures. This measure lowers the risk of carbide segregation. The nominal chemical composition of the new alloy and prehardened stainless are listed in Table 1 (page 28). The new alloy can still be produced by the conventional route, allowing for a cost-effective solution. Now, the homogeneous microstructure of the new alloy is shown in Figure 1b (page 29), where no -ferrite and no carbide segregation were found independent of the ingot position, which corresponds very well with thermodynamic calculations.

Figure 3

N-alloyed prehard stainless

Thermal conductivity of the N-alloyed prehard stainless and X36CrMo17 (1.2316).

the N-alloyed prehard stainless and the classic prehardened modified 420 stainless alloy was investigated in the temperature range between 20C and 500C. Figure 3 shows that the N-alloyed prehard stainless has an improved thermal conductivity. This improvement primarily results from the chemical analysis and the very homogeneous microstructure.

Machinability

Discussion Hardness

The new plastic mold steel is typically supplied in the hardened-andtempered condition at approximately 290 to 330 HB, corresponding to about 32 HRc. In this way, a good combination of machinability, hardness and wear resistance is given.

To determine the influence of the homogenous microstructure of the new alloy on its machinability, a series of tests were done. The machinability of the classic 420 stainless alloy and the new alloy has been tested by rough milling, end milling, drilling, and gun drilling and tapping. Figure 4 shows the results of the drilling test, which exhibits the advanced machinability of the new alloy in comparison to the previous grade. These positive results are due to the very homogenous microstructure without the appearance of carbide segregation.

Corrosion Resistance

Applications
The new alloy uniquely fills the demands that many moldmakers have that are not being addressed today in our marketplace. First, this grade provides good polishability without having to be remelted. This saves on cost for the alloy while still filling the demands of the application. Second, it is a prehardened grade, which saves on heat

To examine the corrosion resistance, salt spray tests were carried out according to DIN 50021, see Figure 2 (page 29). It was found that the corrosion attack was minimized after 2, 4 and 6 hours with the new alloy in comparison to the common 1.2316, which is also a positive result of the homogeneous microstructure. Furthermore both alloys were tested in pitting corrosion measurements. The test medium used was synthetic seawater adjusted to the pH value of 4 using HCl. The pitting potential measured at room temperature of the new nitrogen alloyed prehard stainless is as goodif not better than1.2316.

Thermal Conductivity

Improvements in productivity lead to a reduction in cycle time during plastics processing. As a consequence, plastic mold steels with a higher thermal conductivity are required. The thermal conductivity of

The new alloy uniquely fills the demands that many moldmakers have that are not being addressed today in our marketplace.
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30 MoldMaking Technology | May 2009

Figure 4
N-alloyed prehard stainless (Run 1) DIN 1.2316 (Run 1) N-alloyed prehard stainless (Run 2) DIN 1.2316 (Run 2)

2Lichtenegger, G., Sammer, J., Schneider, R.: Entwicklung eines stickstofflegierten Werkzeugstahles mit hchster Korrosionsbestndigkeit bei grtmglicher Verschleibestndigkeit und Zhigkeit, 1999 3Bauer,

M.: On the Application of Corrosion Resistant Steels for Plastic Molds, in: Jeglitsch, F. (Ed.), 5. International Conference on Tooling, Leoben, Austria, p.669-676, 1999
4Houdremont, 5Ernst,

E.: Handbuch der Sonderstahlkunde, Springer Verlag, p.1298, 1956

C.: Optimized Steel Selection for Applications in Plastics Processing, in: Bergstrm, J. (Ed.), 6. International Tooling Conference, Karlstad, Sweden, p.271-284, 2002
6Ernst,

C., Raschke K.: Nitrogen alloyed tool steels, in: Berns H. (Ed.), International European Conference on Tooling Materials, Interlaken, Switzerland, p.481-499, 1992

N-alloyed prehard stainless

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Comparison of wear of the outer flanks at drilling of the N-alloyed prehard stainless and X36CrMo17 (1.2316) plastic mold steels.

treatment costs and the concerns that most moldmakers have about the heat treatment sequence and how well that process is performed. It provides a grade ready to be machined and put into operation, which saves time and money for the moldmaker. Also, should the moldmaker need a stainless alloy prehardened, this grades unique chemistry gives an overall better corrosion resistance in the prehardened condition than can be obtained in other 420 stainless alloys. Finally, every toolmaker knows that taking a prehardened 420 stainless steel and then machining it in the hardened condition can present some unique machining issues. The modifications done to this alloy will help the toolmaker get a more consistent result and, while not as easy to machine as a resulfurized grade, is still an improvement over the current non resulfurized types. The major applications where this grade can be used is in plastic extrusion tooling where better corrosion resistance is required than a resulfurized stainless alloy can provide. It also should be considered for plastic injection molding and rubber molding where the toolmaker in the past has had to use a 420 remelted stainless because he wanted better polishability than a resulfurized, free machining stainless could provide, but wanted a prehardened grade and did not have it. It also can be considered for holder applications where surfaces of the holder are required to have good polishability and yet the toolmaker would want decent machinability in other areas of the holder.
MMT

Development of a New Mold Base Stainless Steel Due to the intensive machining practices that must be performed on mold bases, if machining time and costs can be reduced, significant savings can be realized. A premium-free machining stainless holder steel has been developed that has optimized chemistry and processing, which lead to greatly improved machinability as well as other important properties. Find a link to this article at http://www.moldmakingtechnology.com/ articles/050901.html.

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Conference Hours June 23-25, 2009: 8:00am-4:15pm McCormick Place, Chicago, IL 11:00am-Noon Session 26 MOLD MATERIAL/MOLD REPAIR Creating and Repairing Plastic Injection Molds Containing Copper-Beryllium Inserts Paul Betz, Century Die Michael Kent, Brush Wellman, Inc. Occupational exposures to airborne beryllium are created by mold fabrication and repair operations. A quantitative exposure survey evaluated workers creating and repairing plastic injection molds. This seminar will review the exposure limits discovered as well as the steps to take to reduce exposure. Visit www.moldmakingexpo.com/conf for Conference Session descriptions and speakers. A MoldMaking Expo 2009 Conference Registration includes a complete conference package and admission to MoldMaking Expo, NPE and Time Compression Expo exhibits: $350 in advance and $500 onsite, so register today! Conference sponsored by

For more information from Bohler-Uddeholm call (800) 638-2520, e-mail Patricia.Miller@bucorp.com, visit www.bucorp.com or visit www.moldmakingtechnology.com.

References
1Gerson,

F.T.: Steel SelectionA Decisive Variable in Design and Construction of Plastics Industry Molds, in: Jeglitsch, F. (Ed.), 5. International Conference on Tooling, Leoben, Austria, p.635-642, 1999

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