Diagnostics and Experiences on Extrusion Press Tooling

Werner Hhnel and Klaus Gillmeister, Kind & Co Edelstahlwerk KG, Wiehl, Germany


ABSTRACT --- The principal range of activities of Kind & Co. Edelstahlwerk is
the development and manufacture of forged tool steels. Equipment includes an
ESR remelting plant, various forging presses, ring rolling mills, annealing plant,
vacuum hardening plant, finished product stocks and mechanical workshop. The
workshop includes a Service Centre for the extrusion press industry, with a
particular focus in replacing liners and repairing used containers. It also provides
a driven metallurgical examination and defect analysis of these components. A
specially established database enables lifelong diagnostic on individual container
and therefore is able to implement a variety of requisite measures to extend its
service life. The following report includes a number of examples shown on
actual tools of an extrusion press and it also illustrates improvement potentials in
the future.


INTRODUCTION

Today, the machinery and equipment technology available serves to optimize the required
characteristics of classical tool steels and to also design new tool steels to accommodate the market
requirements. Particular focus is placed on designing temperature resistant high premium tool steels and top
quality products of high toughness. These premium material qualities stand out because of considerably
reduced share of trace elements in the tool steel.
In close consultation with extrusion press experts, the know-how in developing new tool steels, along
with experience compiled in a focused Service Centre, forms the basis for designing new tools. This
continuous process of improvement leads to increased service life of the tools, a safe and reliable
production process at the extrusion press, enhanced product quality and, consequently, a cost saving.

Table 1. Hot working tool steels for the extrusion press industry.









Domi ni al W.-Nr. Kurzname AISI AFNOR Stahl typ
Mat.-No. Name C Cr Mo Ni V W Co Steel type
KTW 1.2311 40CrMnMo7 ~P 20 40CMD8 0,42 2,00 0,20 - - - Mn 1,50 M
CM 167 1.2323 48CrMoV6-7 - 45CDV6 0,45 1,50 0,75 - 0,30 - - M
USN 1.2343 X37CrMoV5-1 H 11 Z38CDV5 0,38 5,20 1,30 - 0,40 - - M
USD 1.2344 X40CrMoV5-1 H 13 Z40CDV5 0,40 5,20 1,30 - 1,00 - - M
RP 1.2365 32CrMoV12-28 H 10 32DCV12-28 0,32 3,00 2,80 - 0,60 - - M
RPU 1.2367 X38CrMoV5-3 - Z38VDV5-3 0,38 5,00 2,80 - 0,60 - - M
TQ1*) - - - - 0,36 5,20 1,90 - 0,55 - - M
Q 10 - - - - 0,36 5,20 1,90 - 0,55 - - M
HWD 1.2678 X45CoCrWV5-5-5 H 19 Z40KCWV05-05-05 0,40 4,50 0,50 - 2,10 4,50 4,50 M
PW 15 1.2713 55NiCrMoV6 L 6 55NCDV7 0,55 0,70 0,30 1,70 0,10 - - M
PWM 1.2714 55NiCrMoV7 ~L 6 ~55NCDV7 0,55 1,10 0,45 1,70 0,10 - - M
AWS 1.2731 X50NiCrWV13-13 - - 0,50 13,00 - 13,0 0,60 2,40 - M
MA-Rekord 1.2758 X50WNiCrVCo12-12 - - 0,55 4,00 0,60 11,5 1,10 12,00 1,50 M
RPCo 1.2885 X32CrMoCoV3-3-3 H 10A - 0,32 3,00 2,80 - 0,60 - 3,00 M
RM 10 Co 1.2888 X20CoCrWMo10-9 - - 0,20 9,50 2,00 - - 5,50 10,00 M
HMoD 1.2889 X45CoCrMoV5-5-3 H 19A - 0,45 4,50 3,00 - 2,00 - 4,50 M
HWF 1.2779 X6NiCrTi26-15 A286 Z6NCTDV2515B <0,08 15,00 1,50 26,0 - Ti 2,30 - A
SA 718 2.4668 NiCr19Fe19Nb5Mo3 UNS
No
7718
NC19FeNb 0,05 19,00 3,00 53,0 - Nb 5,0
Ti 0,9
Al 0,5
- Ni
SA 50Ni 2.4973 NiCr19CoMo R41 - <0,12 19,00 9,50 Rest
Balance
- Ti 3,0
Al 1,6
11,00 Ni
M = martensi ti sch / martensi ti c
A = austeni ti sch / austeni ti c
Ni = Ni ckel -Basi s-Legi erung / Ni ckel base super al l oy
Ri chtanal yse / Reference Anal ysi s i n Mass-%
*) erzeugt nach dem El ektro-Schl acke-Umschmel zverfahren (ESU)
produced by El ectro-Sl ag-Remel ti ng technol ogy (ESR)
23
Toughness testing
Charpy 10x7x55 mm
Charpy-V 10x10x55 mm
Position of specimen
Tensile testing
MATERIALS TECHNOLOGY

Performance Specification

Particularly in recent years, the performance requirements for extrusion presses have become more
stringent. The market for these extrusion press plants requires high productivity, tooling flexibility for
product diversity and nearly 100-percent availability. From these continuously increasing performance
requirements, the range of materials used for these purpose has also undergone increased development. To
accommodate these demanding needs, a variety of discussions on material characteristics are held on a
continual basis.

Depending on a tools field of application,
focus on different and very important aspects of
the material were considered. The material
structure, analysis and strength as well as
toughness, high temperature strength properties
and abrasive wear resistance. In general, the
declared objective is to make the material
properties generally accepted for process
engineering also apply to characteristics required
for the tools primary and specific function.



Figure 1. Test specimen taken from forged components.

Research And Development Of Steel Grades

When we speak of hot working steels, means the classical martensite Cr-Mo-V alloys that, above all,
stand out for the following characteristics:
- High tempering resistance
- High temperature strength
- High hot wear resistance
- High thermal fatigue resistance

In addition, special tooling applications call for austenite and Ni-based alloy steels in the extrusion press
industry. The underlying
objective of material
development is to exploit the
maximum material potential
along with optimum ductility at
high application hardness.
Again, this is keeping a focus on
the tools primary and specific
function in mind. Without
doubt, the so-called super clean
hot working tool steels, for
example, TQ1 from the top
quality range, constitute a
milestone in material
development in the past 10
years.


Figure 2. Segregation behavior in the different manufacturing processes.

offene Erzeugung ESU-Erzeugung
24
With material H-11 (1.2343) and RPU (1.2367), a success was made in combining the toughness of
one material with the high temperature strength properties of the others. In addition, a modified
manufacturing process, along with the ESU remelting procedure, ensures a quality ranging in the top range.
An integral part of the improvement process is material development that, culminating in the so-called
super clean qualities, enables a decisive enhancement of the material properties itself.
To select only one aspect, i.e., the toughness of materials in the premium range comparing to the TQ1
top alloy, this modified and high purity manufacturing process enables an increase in toughness of up to 30
percent.



















Figure 3. Comparison of toughness on hot working steels

This increase in toughness enables a reduced cracking tendency and, consequently, prolonged service
life at identical tool hardness.
As a result, the tools show an identical toughness level at increased hardness. Particularly with indirect
press stem, the high surface pressing at the stem shaft also requires a material strength increased by about
600 N/mm. So far, this increased material strength of 1,750 to 1,850 N/mm could only be obtained at the
expense of the toughness of the traditional materials such as, for example, H-11 (1.2343). Today, these high
premium steels and top qualities enable us to maintain this high strength level on press stems without any
loss in toughness.
Other fields of application
for these top steels are inner
liners which are produced with
an increased hardness
comparing to traditional hot
working steels. This method
predominantly serves to
prolong the durability of the
sealing face, and to counteract
abrasive wear of the boring
surface and plastic dimensional
changes. As a matter of
consequence, this also ensures
enhanced product quality.
The illustrations show a
number of successful TQ1
applications (stems, liners,
pilger roll and dies).
Figure 4. TQ1 applications.

0
5
10
15
20
25
30
1.2343 1.2344 1.2367 TQ 1
Transverse testing (core section)
320mm
approx. 45 HRC
Charpy-V
1.2343 1.2344 1.2367 TQ 1
Charpy
Individual testing
Toughnes testing
Charpy
10 x 7 x 55mm
1.2343 1.2344 1.2367 TQ1
J
o
u
l
e
Unnotched testing
25
We are currently working with a newly developed high-premium steel called HP1, which will be
distinguished by specific trace elements and feature a toughness and operational efficiency similar to the
TQ-1 but different. The figure below shows HP1 along with its special toughness and high-temperature
strength properties.


























Figure 5. New development of HP1.


MANUFACTURING PROCESS OF FORGINGS

Apart from steel production and alloy composition, the manufacturing process applied has a substantial
influence on the material properties.
Further to standard steel bar forging, our company favors close to finish dimension forging (stem,
liner) and three-dimensional forging (dies) of the tool steels. Both forging methods significantly influence
the characteristics of the tool.















Figure 6. Individual forgings.

Shape / Step forging :
Stems
3D-Individual
Bigger dies ,
AWS (1.2731) -Discs
Individual forging
Container mantles and linersel
Standard bar forging
Simple die material
Samples of forging alternatives

26

This has a positive influence on the microstructure and fibrous structure of the steel. The illustration
below shows a simple flat section made from 2.4379 (SA 50 Ni) from which samples were taken at
different areas to determine the material properties.

Figure 7. Comparison of toughness depending on the forged fiber direction.

The changed fiber direction in press extrusion dies alone has a significant influence on toughness.
In the case of press stems, it is an advantage to forge the rough contour as close as possible to the finished
contour. This entails a more favorable fiber course in the press stem which has a positive effect on its
maximum working stress. This is especially the transition zones between the base and shaft. This specific
stem area is considered a critical danger spot which are considerably improved by means of this open-die
forging technique.




















Figure 8. Contour forging of press stems.

All-round forging of 3d-discs in dies for heavy-metal or light-metal dies is the technique of choice
thanks to its practically isotropic material quality.
In particularly, extrusion dies with asymmetrical break-outs and the resulting tensile, compression or
torsion stresses, require almost identical technological material properties in all three dimensions.
Grain structure
Grain structure
Grain structure
Rond bar forging
Flat bar forging
Grain structure

Grain structure
Grain structure
Mechanical properties after heat treatment
80 mm
1250-1280 N/mm
Transverse specimen
Charpy =38; 48; 66
= 50 Joule
Longitudinal specimen
Charpy =86;103; 130
= 103 Joule
W.-Nr. 2.4973 ( Dominial SA 50 Ni )
Length = 3995 m
m
Shape forging
27
3D
individual
Bar Bar Bar
Size 10 x 7 x 55 mm
ISO
Standard
ESR
Standard
=Special heat treatment
400
500
300
200
100
J
/
c
m

(

4
5

H
R
C
)
Impact Energy H13 / 1.2343





















Figure 9. 3D-forging of a die. Figure 10. Forging a container mantle.

The specific liners required for containers are individually forged in an open-die forging press. After
pre-forging and upsetting, the block is punched and finish-forged on a mandrel rotating in axial direction.
Comparing to traditional bar forging, this forging technique enables an enhanced forming gradient which
has a positive effect on grain structure and ductility.


























Figure 11. Material properties are dependent on the manufacturing technique.



28
HEAT TREATMENT

A further influence on the material properties that is not to be underestimated is heat treatment of the
tool materials. The following parameters are of significant importance:

Initial Structure

The initial structure should be qualified in accordance with the DGM or ASM standards, depending on
end users location.

Heat Treatment Parameters

The austenitizing temperature and holding time are decisive factors for martensitic steels.
For hot working steels, this temperature ranges between 1,000 and 1,130C. Of crucial importance is
thorough heating of the component concerned along with a holding time tailored to the cross sectional
geometry. Depending on the requirement, these parameters are adjusted to fit the individual circumstances.
Whilst overheating or excessive holding of the extrusion press tool may increase its tempering resistance, a
side effect thereof may be undesirable grain growth.

Quenching Rate

Basically, martensitic steels require fast quenching rates to reach the prescribed material properties.
Insufficient cooling rates result in unacceptable transformation structures which have a negative influence
on the material characteristics.




















Figure 12. Comparison of coarse grain/fine grain shown in etched micrograph.

Tempering

Repeated tempering process does not only serve to adjust the required tensile strength but also entirely
converts residual austenite to martensite. If this procedure is not pursued, the toughness potential of the
material is not fully utilized. Tempering the material 3 times is, therefore, recommended.
In order to achieve the optimum material potential the parameters indicated must be observed. More
often than not, this best possible heat treatment technique is disregarded for reasons of cost and pressing
time schedules and, as a result, the maximum steel properties are not fully taken advantage of.



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SURFACE TREATMENT TECHNIQUES

Surface treatment techniques are used to reduce frictional resistance and adhesive tendency or to
generate a non-metallic insulating layer on extrusion press tools. The following is more detailed
information on two significant surface treatment techniques.

Nitriding

Nitriding describes the concentration with atomic nitrogen on the skin layer of a work piece. This
concentration serves to produce a non-metallic surface and an increase in surface hardness to approximately
1,200HV.
The nitriding process is used on dies for aluminum sections and enables a reduced adhesive tendency
and enhanced wear resistance of the die.
The following composition of a nitrided layer is recommended:

White layer zone (white layer): 6 to 10 m
Diffusion zone: 0.10 to 0.15 mm.











Figure 13. Composition of a nitrided layer.


Oxidizing

A further surface treatment technique for use on mandrels for copper tubes is a special oxidizing
procedure. The oxidized surface yielded by this technique enables optimum starting conditions on mandrels
for tubes comparing to non-treated mandrels. The layer thickness produced is approximately 4 to 6 m.











Figure 14. Oxide layer on extrusion press mandrels.

Both techniques have become well established and ensure extended holding times of the tools and an
enhanced quality of extrusion press products.



30
INSPECTION AND SHRINKING TECHNIQUE

The individual components of each container, such as mantle, intermediate liner, and internal liner, are
subjected to a particular stress situation that makes replacement of the liner inevitable. In the course of
these activities, the container undergoes comprehensive inspection in order to draw conclusions regarding
further use or additional measures to be implemented.
General testing, such as dimensional checks and visual inspections for cracks, are all very important to
the service life of the container. Precise examination of the delicate openings for temperature sensors and
air inlets are vital as well. Boroscopes provide the means to inspect these crucial and hard-to-get-to areas
and provide critical details of these areas.

Database Inspection

At the service centre, all inspection results and measurements implemented are set up on a special
database to enable a comprehensive history of the container and to develop a continuous enhancement
process jointly with the customer. Along with the customer production information, the database becomes
an invaluable resource for the container history, for future considerations and for design modifications.
New developments such as the AP system, WT cooling, and modified heating connection, which will
be described in more detail later, are a result of this continuous enhancement process.
All the important information is documented on the database and is available for future evaluation for
each customer.

Shrinking Technique

During practical operation, the container is subjected to continuously changing mechanical-thermal
stress conditions. Aside from the specific stress created by the billet and container temperatures, shrinkage
stress is an important factor for consideration in application-related stress calculations. It is of major
importance to account for the different expansion coefficients of the materials used for container assembly.

ENGINEERING AND DESIGN

Besides from the optimal materials characteristics, in respect of their composition, hardness, structure,
microstructure, toughness, high temperature strength and wear resistance, the container design and
supportive engineering also bear a considerable development potential for the improvement of extrusion
tools. The following examples illustrate these developments.

Air Protection System (AP system, registered design 203 18 917.5)

On air-cooled container recipients, an AP system serves to ensure safe and smooth operation. After
comprehensive examinations on a number of surface cracks on air supply bores, a new design was
developed for a protective tube.
Without the AP system, the container bore, at the air supply bores, showed axial cracks, which
required meticulous milling and welding.
The new AP system has now been in operation for several years, and all recipients equipped with this
system are found to be without cracks at the critical locations.
Checkups are digitally documented by means of a boroscope.









31
WT- Cooling System
(registered design)

Figure 15. Container mantle before and after installing AP system.


Heat Exchanger Cooling (WT cooling, registered design 201 17 589.4)

The incoming radial air flow into the recipient is directed to the intermediate liner via spiral-wound
cooling elements. To enlarge the surface and generate turbulent flow, the cooling element topography has a
corrugated outline.
This design is intended to increase the number of internal liners per installed intermediate liner.
So far, about two internal liners could be used with the same internal liner on heavy-metal extrusion
presses. Based on initial test results we were able to install three internal liners in the same intermediate
liner.





Figure 16. WT cooling on an intermediate liner.

Power Connection for Heating System

The container connection to the heating system is a sensitive area that requires particular examination
for cracks during our incoming inspection. It is, therefore, of major importance to keep the number of
tapped holes for attachment of connections to the heating system to a minimum.



32



Figure 17. Damage to connections to heating
system.
Figure 18. Modified connection to heating system.


As shown in Figure 18, the tapped holes are omitted in the particularly critical areas of the shell without
any loss of stability.

Moreover, the engineering concept must account
for the fact that the radiuses and transition areas
are generously dimensioned in order to avoid
inevitable cracks.










Figure 19. Radiuses and transitions at critical areas.

Protection of Liners Against Movement

The inner and intermediate liners in the container are protected against axial movement by means of
positive or negative shoulders. If the container is operated in both directions, a double shoulder should be
installed on the inner and/or intermediate liner.
The double shoulder prevents displacement of the liners in either direction. A disadvantage is the
increased expenditure in time required for the replacement procedure. The liner is cooled with nitrogen and
positioned into the preheated mantle. In addition, the double shoulder needs to be machined before
shrinking out the liner.











33























Figure 20. Design variants of shoulders on inner and intermediate liners.

The expansion coefficient on austenite liners is increased by 40 percent compared to martensite grades
and must be accounted for accordingly on selecting the shoulder design.
Due to physical characteristics, the positive shoulders leave a small gap of 2 to 3 mm. During practical
operation, the liner settles again to close this gap. This gap is practically not found on negative shoulders,
which makes this option a preferred design on state-of-the-art light-metal containers.

Preheating Of Container

Prior to start-up, the container should be preheated to at least 710 to 750F (380 to 400C) throughout.
Preferably, this preheating process should be conducted outside the press at an external preheating station.

Press Stem

As already mentioned, press stems are subjected to increasing specific compression stresses.
Accordingly, premium hot working tool steels with increased hardness factors are used. Apart from the
steel, however, the design is being optimized as well. Particularly the transition areas between a square base
and the round shaft are frequently susceptible to cracks as shown in the picture. Design changes along with
the use of the extremely tough material TQ1 ensure operational safety.













Figure 21. Damage on press stem.
Positive - Positive
Mantle
Sleeve
Liner
Positive - Double shoulder
Mantle
Sleeve
Zwischenbchse
Liner
Positive - Negative
Mantle
Liner
Sleeve
Negative - Negative
Mantle
Liner
Q 10 ! Q 10 !
Sleeve
34
SUMMARY

Continually changing specification requirements in the extrusion press industry equally requires a
continuous research and development process with respect to materials, production, and design. This
continuous process is supported by an intelligent database system.
Information compiled on the basis of diagnosed cases of damage, along with experience gained at the
extrusion press facilities, are fed into this database system so that we are able to pursue targeted product
enhancement jointly with users.
Based on practical examples, this report represents a survey on the development steps reached so far. A
wide-spread production range along with know-how enables continuous developments on extrusion press
tools, which are then implemented in a safe manufacturing process.
Our experience has shown that it is impossible to completely transfer individual developments and
improvements to comparable users on a global basis. The true individual benefits to the customers are when
there is a direct and open exchange of information between supplier and user. The exchange clarifies and
defines the design and the real benefits.

LITERATURE

1. Books
Laue / Stenger, Strangpressen
M. Bauser / G. Sauer / K. Siegert, Strangpressen

2. Patents
Kind & Co. Edelstahlwerk, Registered German Patent 203 18 917.5, AP System
Kind & Co. Edelstahlwerk, Registered Austrian Patent GM 874/2003, AP System
Kind & Co. Edelstahlwerk, Registered German Patent 201 17 589.4, WT Khlung
35