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UDDEHOLM
STAVAX ESR
STAVAX ESR
REFERENCE STANDARD
ASSAB DF-2
ARNE
ASSAB DF-3
AISI
WNr.
JIS
O1
(1.2510)
(SKS 3)
O1
(1.2510)
(SKS 3)
D6 (D3)
(1.2436)
(SKD 2)
ASSAB XW-5
SVERKER 3
ASSAB XW-10
RIGOR
A2
1.2363
SKD 12
ASSAB XW-41
SVERKER 21
D2
1.2379
SKD 11
1.2379
SKD 11
ASSAB XW-42
D2
CARMO
CARMO
1.2358
CALMAX
CALMAX
1.2358
CALDIE
CALDIE
ASSAB 88
SLEIPNER
ASSAB PM 23 SUPERCLEAN
VANADIS 23 SUPERCLEAN
(M3:2)
1.3395
SKH 53
ASSAB PM 30 SUPERCLEAN
VANADIS 30 SUPERCLEAN
(M3:2 + Co)
1.3294
SKH 40
ASSAB PM 60 SUPERCLEAN
VANADIS 60 SUPERCLEAN
VANADIS 6 SUPERCLEAN
VANADIS 6 SUPERCLEAN
VANADIS 10 SUPERCLEAN
VANADIS 10 SUPERCLEAN
VANCRON 40 SUPERCLEAN
VANCRON 40 SUPERCLEAN
ELMAX SUPERCLEAN
ELMAX SUPERCLEAN
(1.3292)
ASSAB 518
P20
1.2311
ASSAB 618
P20 Mod.
1.2738
ASSAB 618 HH
P20 Mod.
1.2738
ASSAB 618 T
P20 Mod.
1.2738 Mod.
IMPAX SUPREME
P20 Mod.
1.2738
ASSAB 718 HH
IMPAX HH
P20 Mod.
1.2738
NIMAX
NIMAX
MIRRAX 40
MIRRAX 40
420 Mod.
VIDAR 1 ESR
VIDAR 1 ESR
H11
1.2343
SKD 6
UNIMAX
UNIMAX
CORRAX
CORRAX
420
1.2083
SUS 420J2
1.2083 ESR
SUS 420J2
1.2714
SKT 4
ASSAB 2083
STAVAX ESR
STAVAX ESR
420 Mod.
MIRRAX ESR
MIRRAX ESR
420 Mod.
POLMAX
POLMAX
RAMAX HH
RAMAX HH
ROYALLOY
ROYALLOY
420 F Mod.
PRODAX
ASSAB PT18
ASSAB MMXL
ASSAB MM40
ALVAR 14
ALVAR 14
ASSAB 2714
ASSAB 8407 2M
ORVAR 2M
ORVAR SUPREME
DIEVAR
DIEVAR
HOTVAR
HOTVAR
QRO 90 SUPREME
QRO 90 SUPREME
1.2714
SKT 4
H13
1.2344
SKD 61
H13 Premium
1.2344 ESR
SKD 61
ASSAB 705
4340
1.6582
SNCM8
ASSAB 709
4140
1.7225
SCM4
ASSAB 760
1050
1.1730
S50C
STAVAX ESR
STAVAX ESR
The plastic product is only as good as the surface finish of the mould steel
in which the product is formed. The presence of non-metallic inclusions
and segregation within the steel, limit the polishability of the mould steel.
Thanks to the electroslag remelting (ESR) process that is utilised to
produce Stavax ESR, this steel is capable of being polished to a very high
surface finish. The ESR process is an additional step during the steelmaking,
which ensures very clean steel with low sulphur content (0.003% max.) and
non-metallic inclusions.
Stavax ESR is an excellent choice for small and medium inserts and cores.
Properties
Stavax ESR combines corrosion and wear resistance with excellent
polishability, and offers good machinability.
Advantages
Clean and homogeneous mould steel improves polishability, photoetchability
and texture.
Benefits
Reduce mould maintenance as the mould made of Stavax ESR maintains
its original surface finish over a long period of production.
When compared with non-stainless mould steels, Stavax ESR offers
lower production costs through clean cooling channels that assure
uniform cooling and consistent cycle times.
Especially suitable for applications within the medical industry, optical
industry and for other high quality transparent parts when rust in
production is unacceptable and where requirements for good hygiene
are high.
Stavax ESR is a product within the ASSAB Stainless Concept.
The Stainless Concept is our own programme of metallurgically balanced
stainless grades that has been specially developed and continually expanded
to meet the needs of todays fast-changing plastic moulding industry. The
problems are well known: rust problems with moulds, surface that need
repolishing, cooling channels that have to be redrilled, and parts that
rust together. Choosing the right product within our Stainless Concept,
which can be used individually or in combination to produce the highest
quality tooling for the full range of moulding applications, will minimise the
problems above.
STAVAX ESR
General
Applications
Corrosion/staining resistance
Moulding of corrosive plastics, e.g., PVC, acetates,
and for moulds subjected to humid working/storage
conditions.
excellent polishability
good wear resistance
good machinability
good dimensional stability during heat treatment
The combination of these properties provides a steel
with outstanding production performance. The practical
benefits of good corrosion resistance of a plastic mould
can be summarised as follows:
Lower mould maintenance costs
The surface of cavity impressions retain their original
finish over an extended service life. Moulds stored
or operated in humid conditions require no special
protection.
Lower production costs
Since cooling channels are less likely to be affected
by corrosion (unlike conventional mould steels),
heat transfer characteristics, and therefore cooling
efficiency, are constant throughout the mould life,
ensuring consistent cycle times.
Wear resistance
Moulding abrasive/ filled materials, including injection
moulded thermosetting grades. Stavax ESR is
recommended for moulds with long production runs,
e.g., disposable cutlery and containers.
High surface finish
Production of optical parts, e.g., camera and sunglass
lenses. Moulding of medical components, e.g., syringes
and analysis vials.
C
0.38
Si
0.9
Mn
0.5
Cr
13.6
V
0.3
Standard
specification
Delivery condition
Colour code
Black / Orange
Stavax ESR is the right choice for lens mould with extreme
demand on polishability.
Type of mould
Recommended
hardness HRC
45-52
45-52
50-52
45-52
45-52
STAVAX ESR
Properties
PHYSICAL DATA
Hardened and tempered to 50 HRC.
Temperature
20C
200C
400C
Density
kg/m3
7800
7750
7700
Modulus of elasticity
MPa
200 000
190 000
180 000
Coefficient of
thermal expansion
per C from 20C
11.0 x 10 -6
11.4 x 10 -6
Thermal conductivity
W/m C
19
20
24
Specific heat
J/kg C
460
CORROSION RESISTANCE
TENSILE STRENGTH
The tensile strength values are to be considered as
approximate only. All samples were taken from a bar
(in the rolling direction) with 25 mm diameter.
Hardened in oil from 1025 10C and tempered twice
to the indicated hardness.
Hardness
50 HRC
45 HRC
Tensile strength, Rm
1780 MPa
1420 MPa
1460 MPa
1280 MPa
Corrosion
resistance
100
200
300
400
500
Tempering temperature
600C
STAVAX ESR
Heat treatment
Hardness, grain size and retained austenite as a
function of austenitising temperature
SOFT ANNEALING
Protect the steel and heat through to 890C. Then cool
in the furnace at 20C per hour to 850C, then at 10C
per hour to 700C, then freely in air.
Grain size
ASTM Hardness, HRC
60
10
STRESS RELIEVING
58
8
7
56
54
52
50
48
HARDENING
4
3
46
44
42
40
Temperature
C
Soaking time
minutes
Hardness before
tempering
Retained austenite, %
Grain size
Holding time
60 min.
40
30
Retained
austenite
Holding time
20 min.
20
10
QUENCHING MEDIA
1020
30
562 HRC
1050
30
572 HRC
Hardness, HRC
Warm oil, approx. 80C
60
Retained austenite, %
14
1050C
In order to obtain optimum properties
for the tool, the
55
cooling rate should be fast, but not at a rate that gives 12
CCT graph
40
Retained
austenite
1030C
35
C
1100
30
4
2
1000
100
900
= 980C
200
300 AC400
500
600C
1f
Tempering temperature (2 x 2h)
AC = 860C
1s
800
Pearlite
Carbides
700
Dimensional change, %
+0.16
+0.12
600
500
400
+0.04
MS
300
Mf
Martensite
100
10
100
1
1 000
10
1.5
- 0.08
- 0.12
8
100
100
10
1 000
Minutes
10
90
649
634
613
592
585
421
274
500
206
1
31
105
316
526
1052
2101
600
4204
200 300
Tempering temperature (2 x 2h)
100 000 Seconds
10 000
1
0.2
1
2
3
4
5
6
7
400
8
0
- 0.04
200
Cooling
Curve Hardness T800500
HV 10
sec.
No.
+0.08
600
100 Hours
Air cooling
of bars, mm
700C
Grain size
58
8
7
56 60 min.
54
52
50
48
4
3
2
1
46
44
42
Holding time
40
STAVAX ESR
30
Holding time
20 min.
Retained
austenite
20
DIMENSIONAL
CHANGES
40
10
960 980 1000 1020 1040 1060 1080C
Austenitising
temperature
The dimensional changes
during
hardening and tempering
Grain size
ASTM Hardness, HRC
60
10
58
8
7
56 60 min.
54
52
Retained austenite, %
Grain size
Holding time
40
30
20
55
Dimensional
changes during hardening
12
50
10
An example of dimensional
1020Cchanges on a plate, hardened
under
ideal conditions 100 x 100 x 25 mm is shown below. 8
45
40
Hardening from
Width
1020C
%
Retained
35
austenite
Martempered
Min.
+0.02
1030C -0.03
30
Max.
Length
%
0
+0.03
Thickness 6
%
4
-0.04
2
Air hardened
25
100
Min.
-0.02
0
0
200
500
600C Max. 300+0.02400
-0.03
Tempering temperature (2 x 2h)
Vacuum hardened Min.
+0.01
0
-0.04
Max.
-0.02
+0.01
-
Austenitising temperature
Hardness, HRC
60
55
Retained austenite, %
14
1050C
12
50
10
1020C
45
40
6
Retained
austenite
1030C
30
25
100
Dimensional change, %
+0.16
+0.12
+0.08
+0.04
Tempering graph
35
0
- 0.04
- 0.08
- 0.12
100
200 300
400 500
600
Tempering temperature (2 x 2h)
700C
4
2
200
300
400
500
600C
Tempering temperature (2 x 2h)
Dimensional change, %
+0.16
Tempering at 250C is recommended for the best combination
+0.12
+0.04
A
combination of high austenitising temperature and low
0
tempering
temperature <250C gives a high stress level
in
the mould, and should be avoided.
- 0.04
- 0.08
- 0.12
100
200 300
400 500
600
Tempering temperature (2 x 2h)
700C
STAVAX ESR
Machining recommendations
The cutting data below are to be considered as guiding
values and as starting points for developing your own
best practice.
MILLING
Face and square shoulder milling
TURNING
Cutting data
parameters
Turning
with HSS
Rough milling
Fine milling
Cutting speed
(vc)
m/min
180 - 260
260 - 300
Feed (f z)
mm/tooth
0.2 - 0.4
0.1 - 0.2
2-4
0.5 - 2
P20 - P40
Coated carbide
P10 - P20
Coated carbide
or cermet
Rough
turning
Fine
turning
Fine
turning
Cutting speed
(vc)
m/min
160 - 210
210 - 260
18 - 23
Feed (f)
mm/r
0.2 - 0.4
0.05 - 0.2
0.05 - 0.3
2-4
0.5 - 2
0.5 - 3
Carbide
designation
ISO
P20 - P30
Coated
carbide
P10
Coated
carbide or
cement
End milling
Type of milling
Cutting data
parameters
DRILLING
Solid
carbide
Carbide
indexable
insert
High speed
steel
120 - 150
170 - 230
25 - 301
Feed (f z)
mm/tooth
0.01 - 0.022
0.06 - 0.22
0.01 - 0.302
Carbide
designation
ISO
P20 - P30
Cutting speed
(vc)
m/min
Feed (f)
mm/r
12 - 14*
0.05 - 0.10
5 - 10
12 - 14*
0.10 - 0.20
10 - 15
12 - 14
0.20 - 0.30
15 - 20
12 - 14*
0.30 - 0.35
GRINDING
Wheel recommendation
Carbide drill
Type of grinding
Soft
annealed
condition
Hardened
condition
A 46 HV
A 46 HV
A 24 GV
A 36 GV
Cylindrical grinding
A 46 LV
A 60 KV
Internal grinding
A 46 JV
A 60 IV
Profile grinding
A 100 LV
A 120 KV
Type of drill
Cutting data
parameters
Cutting speed
(vc)
m/min
Feed (f)
mm/r
1
Indexable
insert
Solid
carbide
Carbide
tip
210 - 230
80 - 100
70 - 80
0.03 - 0.101
0.10 - 0.251
0.15 - 0.251
STAVAX ESR
Polishing
Welding
There is a general tendency for tool steel to crack
after welding. When welding is required, take proper
precautions with regards to joint preparation, filler
material selection, preheating, welding procedure and
post weld heat treatment to ensure good welding
results.
For best result after polishing and photo-etching, use
the recommended filler materials as shown in the table
below.
Welding method
Preheating
temperature1
TIG
MMA
Filler material
STAVAX
TIG-WELD
Maximum interpass
temperature2
Postweld cooling
STAVAX
WELD
Photo-etching
Stavax ESR has a very low content of slag inclusions,
making it suitable for photoetching. The special photoetching process that might be necessary because of
Stavax ESRs good corrosion resistance is familiar to all
the leading photo-etching companies.
Further information
For further information, i.e., steel selection, heat
treatment, application and availability, please contact our
ASSAB office* nearest to you.
*See back cover page
Hardness after
welding
54 - 56 HRC
Hardened condition
Soft annealed
condition
A clean steel with very good polishability gives the final medical
product an excellent surface finish.
STAVAX ESR
Plastic
deformation
Cracking
Wear
Corrosion
Polishability
Thermal
conductivity
Machinability
618
ROYALLOY
718 HH
NIMAX
CORRAX
POLMAX
MIRRAX ESR
STAVAX ESR
8407 SUPREME
UNIMAX
ELMAX
XW-10
HOT WORKING
From the ESR plant, the steel goes ot the rolling mill or
to our forging press to be formed into round or flat bars.
Prior to delivery, all bar materials are heat treated to
either soft annealed condition or hardened and tempered
condition.
MACHINING
ESR PLANT
In uphill casting, a controlled flow of molten steel from
the ladle filled the prepared moulds, and solidifies into
ingots.
10
STAVAX ESR
10
Plastic
deformation
Cracking
Wear
Corrosion
Polishability
Thermal
conductivity
Machinability
STAVAX ESR
Ningbo
ASSAB Tooling Technology
(Ningbo) Co., Ltd.
Tel : +86 574 8680 7188
Fax: +86 574 8680 7166
info.ningbo@assab.com
Cikarang*
PT. ASSAB Steels Indonesia
Tel : +62 21 461 1314
Fax: +62 21 461 1306/
+62 21 461 1309
info.cikarang@assab.com
MALAYSIA
Kuala Lumpur - Head Office
ASSAB Steels (Malaysia) Sdn. Bhd.
Tel : +60 3 6189 0022
Fax: +60 3 6189 0044/55
info.kualalumpur@assab.com
Jiangxi*
ASSAB Tooling (Dong Guan)
Co, Ltd., Jiangxi Branch
Tel : +86 769 2289 7888
Fax : +86 769 2289 9312
info.jiangxi@assab.com
11
STAVAX ESR