CREATING VALUE FOR THE WORLD

DOOSAN PLASTIC MOLD STEEL

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION

GLOBAL LEADER IN POWER & WATER

Doosan has continued to research and develop technology for producing outstanding mold steel, which is now being supplied for the benefit of customers worldwide. Plastic mold steel from Doosan is also accelerating the development of industry.

PLASTIC MOLD STEELS

CONTENTS
PLASTIC MOLD STEELS HP1A / HP4A(D1) / HP4MA(D2) HIGH QUALITY PLASTIC MOLD STEELS HP70 / HEMS1A PHYSICAL PROPERTIES MANUFACTURING PROCESS 10 13 14 6

03

PLASTIC MOLD STEELS

INTRODUCTION

Polishing Property (Schematic Diagram)

HP70 HP4MA(D2)
Hardness >

HEMS1A

HP4A(D1) HP1A
General Products Semi-Transparent Products Transparent Products Super mirror finish Products

Mirror Polishability >

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION

Doosans 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, ship building to cement industries. Since being founded, DOOSAN has also supplied plastic mold steels and tool steels to the high technology sectors such as electric, electromagnetic, optical, telecommunication industries as well as the fields of semiconductors, 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 patents for 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. We will promise satisfaction to all of our customers. New types of high-quality free-cutting steel for plastic moldings, HP series plastic mold steels, have been developed under a strict quality assurance system with DOOSANmodern facilities. s Compared with the conventional steel materials of other companies, the machining time for our new products can be reduced by a maximum of 40%. Because of special alloy elements in our HP series plastic mold steels, one can obtain better etching workability, polishing workability and weldability than in many other products. As a result, not only is the efficiency of metal mold work improved and the service life of the cutting tools greatly extended, but one can also make excellent plastic products. HP steels and HEMS1A are high performance and high-precision plastic mold steel. Use of our newly developed HP steels and HEMS1A can make a major contribution to the improvement productivity and rationalization of production.

DOOSANs Plastic Mold Steels

DOOSAN BRAND D/N
HP1A

REFERENCE SPECIFICATION DIN

1.1210 Improved 1.2311 Improved 1.2738 Improved

AISI
1050 Improved 4140 Improved P20 Improved

JIS
S55C Improved SCM44O Improved SNCM Improved

ASSAB
618 Improved 718 Improved

SUPPLIED CONDITION
Prehardened

APPLICATIONS
General purpose large size mold base

HP4A(D1)

Core & Cavity Prehardened General purpose mold for Mass-production Higher hardness mold Bumper mold Prehardened General purpose mold for Mass-production Prehardened High grade mold base for mirror surface & EDM requirement Corrosion resistant precision plastic mold Glass mold & TV braun tube mold

HP4MA(D2)

HP70

P21 Improved

Daido s NAK80

HEMS1A

1.2083 Improved

420 Improved

SUS420J2 Improved

STAVAX Improved

Annealed

05

PLASTIC MOLD STEELS

HP1A / HP4A(D1) / HP4MA(D2)

Material Characteristics
HP1A
General Purpose for Plastic Molding Outstanding Machinability Less Residual Stress and Distortion

HP4A(D1)
Excellent Machinability Superior Cleanliness, Weldability and Photo-etching Better Hardness Distribution

HP4MA(D2)
Better Machinability Outstanding Hardness Distribution and Wear Resistance Superior Cleanliness and Photoetching

Manufacturing Characteristics
MELTING
Superior Cleanliness due to High Vacuum Degassing Process

FORGING
No Solidification Defect by Using 130MN & 42MN Press

HEAT TREATMENT
Excellent Mechanical Properties by Optimal Heat Treatment

Main 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%)

Mechanical Properties
Material Surface Hardness Yield Strength (N/mm2) Tensile Strength (N/mm2) HP1A HS 28~33 HP4A(D1) HRc 28~32 HP4MA(D2) HRc 31~34

Material C Ni Cr Mo Special Alloy

HP1A >0.50 <0.50 -

HP4A(D1) 0.25 ~ 0.35 0.20~0.50 1.00 ~ 1.50 0.20~0.40 Added

HP4MA(D2) 0.25 ~ 0.35 0.20~0.50 1.50 ~ 2.00 0.30~0.60 Added

350 ~ 450

650 ~ 800

750 ~ 900

700 ~ 800

800 ~ 900

900 ~ 1100

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Photo etching
There is no serious trouble in the most segregated part of 770mm heavy block.

HP4A(D1)

HP4MA(D2)

Segregation
HP4A (D1) and HP4MA (D2) are superior to HP1A in segregation.
HP1A HP4MA(D2)

Mechanical Properties Graph

Yield Tensile
Hardness (HRc)

Cross Sectional Hardness Distribution

Hardness is uniformly distributed throughout the cross section

Strength(N / )

1000 900 800 700 600 500 400 300 200 100

36 34 32 30 28 26 24 22 20 HP4MA (D2) HP4A (D1)

HP1A

HP4A (D1)

HP4MA (D2)

-200

-100

100

200

Distance from center(mm)

07

PLASTIC MOLD STEELS

HP1A / HP4A(D1) / HP4MA(D2)

Machinability
HP4A(D1) & HP4MA(D2) give 2 times longer in life of tool and shorter in machining time than DIN materials.
VBmax (mm)

TEST CONDITION
Cutter : M415SP-05R-12 V=250m/min f=0.15mm/tooth Insert : SPKN1203EDTR-HP/ TT7070 d=2.0mm Center cutting dry

0.7 1.2311 0.6 0.5 0.4 0.3 0.2 0.1 0.0 0 1 2 3 4 Cutting Distance (mm) Life of tool HP4A(D1)

VBmax (mm)

0.7 0.6 0.5 0.4 Life of tool 1.2738 HP4MA(D2)

1.6

3.3

0.3 0.2 0.1 0.0 0 1

1.5

3.2

4 Cutting Distance (mm)

Procedures for Repair Welding

In 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.
Description Repair Welding Manual HP1A
AWS ER70S-4 ER70S-6 25050 (200~300)
Welding (250~350 ) Preheating

HP4A(D1)
AWS ER80S-B2 ER80S-G 30050 (250~350)
Post Heating TP 30(min) / inch

HP4MA(D2)
AWS ER80S-B2 ER80S-G ER9OS-B3 25050 (200~300)

Remarks

Filler Metals

Welding Rod : 1.6, 2.4

Preheat Temp.

Fuel : LNG Fuel Pressure : 0.5 kg/cm2 TP (Holding Temperature) HP1A : 27020 HP4A(D1) : 35020 HP4MA(D2) : 32020

Post Heat Treatment

PWHT

Post-Weld Heat Treatment (PWHT)

max.100 C/hr Welding (200~350) * Preheating

(500~600) 1-2hr Slow cooling (50/hr)

Required Polishing and Etching Workability

300

*Slow cooled using insulating materials.

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Weldability
Improved consistency in hardness before/after PWHT.

Hardness (Hv)

500 450 400 350 300 250 200 150 500 450 400 350 300 250 200 150 0 2 4 6 8

HP4A(D1). Surface
as weld after PWHT

HP4A(D1). Center
as weld after PWHT

WELD

HAZ

BASE
10

Vickers Hardness (Load:5kg)

650

HP4MA
600 550 500 450 400 350 300 250 200 150 -25
as weld after PWHT

HP4MA(D2)
as weld after PWHT

BASE
-20 -15

HAZ
-10 -5

WELD
0 5 10

HAZ
15

BASE
20 25

Distance from the center (mm)

09

PLASTIC MOLD STEELS

HP70 / HEMS1A
Characteristics
HP70
Maintain excellent surface finish Uniform hardness throughout the cross section Extreme hardness and superior wear resistance Excellent electric discharge machinability

HEMS1A
Excellent corrosion resistance Excellent mirror finishing High precision Uniform hardness throughout the cross section

Quality Properties

Vacuum-Degassing Process
Our free cutting steels are vacuum-degassed and forged. They have 1) excellent cleanliness 2) no pin holes 3) desegregation of alloy elements.

Chemical Compositions
Chemical Composition(wt, %) Material HP70 HEMS1A C < 0.25 0.25~ 0.30 Ni > 2.00 0 ..30 Cr 12.00 ~ 12.50 Mo < 0.50 0.50 Special Alloys Added Added

Mechanical Properties
Material HP70 HEMS1A Yield Strength (kgf/mm2) 100 ~ 115 60 ~ 70 Tensile Strength (kgf/mm2) 120 ~ 135 75 ~ 85 Elongation (%) > 17 > 25 Reduction of Area (%) > 52 > 50 Surface Hardness (HRc) 37 ~ 41 23 ~ 52

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Cross-Sectional Hardness Distribution

Hardness (HRc) HP70 71 60 50 39 HEMS1A (after Q+T)

Hardness (HRc)

50

45

40 30

35 30 26 -250 -200 -150 -100 -50 0 50 100 150 200 250

50

Distance from center (mm)

0 50 100 Distance from the surface (mm)

Machinability
Table Moving Speed: 160mm/min. Face Milling Condition Cutting Speed: 261m/min. Insert Type: SPKN1504EDR Lubricant: No Tensile Strength (kgf/mm2)

High Temperature Tensile Properties

Cutting Force (N)

800 700 600 500 400 300 200

120 100 80 60 40 20 0 HP70

HP70

1.0

1.5

2.0 Cutting Depth (mm)

100

200

300

400

Temperature (0C)

Nitriding Characteristics
Hardness (Hv) HP70

Electric Discharge Machining

HP70

Hardness (Hv)

800 700 600 500 400 520 0C, 5hr

500 450 400 350 300 250 Heat Affected Layer EDM Condition : M/C: Tron150c : Electrode: Copper(8) : Surface roughness: Ra4 8 10 12 14 16 18 20 Distance from the surface (10-2 mm)

470 0C, 5hr

300 200 0 5 10 15 20 25 30 35 40 0 2 4 6 Distance from the surface (10-2 mm)

11

PLASTIC MOLD STEELS

HP70 / HEMS1A

Heat Treatment
Material
0

Heat Treatment Conditions Quenching ( C) Tempering ( C) 100 ~ 500 550 ~ 700

Surface Hardness (HRc) 45 ~ 52 23 ~ 33

HEMS1A

1000 ~1050 oil cooling

Cleanliness
HEMS1A steel, being treated with vacuum-degassing and ESR process, shows an excellent cleanliness.
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0

Corrosion Resistance
5% hydrochloric acid

Weight Loss (g/g)

Cleanliness (%)

0.20

0.15

0.10

0.05

0.00

AISI 420

HEMS1A

AISI 420

HEMS1A

Tempering Hardness Curve

65 60 55 50 45 40 35 30 25 as 100 quenched 200 300 400 500 600 Quenching Temp. : 1025 0C HEMS1A

Hardness (HRc)

Tempering Temperature (0C)

Polishing Workability
Fig. shows workability of polishing and finishing.
Material HP70 HEMS1A Ra.( 0.019 0.01 ) Rmax.( 0.167 0.03 ) Remark 1 Diamond paste use

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PHYSICAL PROPERTIES

Physical Properties
Temperature
(0C) Room temperature

Material

Thermal conductivity
(W / m K)

Specific heat
(Cal / g 0C)

Coefficient of thermal expansion

(10-6 / 0C)

50.242 48.148 44.799 41.031 42.287 41.868 40.193 37.263 40.612 40.193 39.356 37.681 33.1176 33.5781 32.9920 31.1917 28.8052 26.0838 22.1482 25.121 26.377 27.214 28.052

0.116 0.125 0.132 0.138 0.115 0.124 0.131 0.137 0.117 0.126 0.135 0.139 0.499 0.513 0.544 0.597 0.644 0.728 0.766

13.76 14.51 15.36 15.81 16.22 16.54 13.87 14.32 14.82 15.58 15.75 16.08 11.82 13.23 14.16 14.64 14.89 15.14 12.89 12.44 13.38 14.01 14.17 14.56 11.6 11.9 12.4 12.7

HP1A

100 200 300 400 500 600

Room temperature 100

HP4A(D1)

100 200 300 400 500 600

Room temperature 100

HP4MA(D2)

100 200 300 400 500 600

Room temperature 100

HP70

100 200 300 400 500 600 100 200 300 400

HEMS 1A

13

PLASTIC MOLD STEELS

MANUFACTURING PROCESS
Manufacturing Process

1. Melting

>

2. V.S.D(Ingot Making by Vacuum Steam Degassing)

>

3. E.S.R

>

4. Heating

>

5. Forging

>

6. Heat Treatment

>

7. Inspection

Melting

Machining Refining Ingot Making in Vacuum Condition Heating Forging Preliminary Heat Treatment

Vacuum Degassing

Ingot Making

E.S.R

Shipment

Inspection

Quality Heat Treatment

GLOBAL NETWORK
Overseas Branches
DOOSAN HEAVY INDUSTRIES AMERICA CORP. Parker Plaza, 10th Floor 400 Kelby Street Fort Lee, NJ 07024, U.S.A. Tel 1-201-944-4554 Fax 1-201-944-5022, 5053 NEW JERSEY OFFICE Parker Plaza, 10th Floor 400 Kelby Street Fort Lee, NJ 07024, U.S.A. Tel 1-201-944-4554 Fax 1-201-944-5022, 5053 PITTSBURGH OFFICE C/O Westinghouse Electric Company, Suite E361B, 4350 Northern Pike, Monroeville, PA 15146 U.S.A. Tel 1-412-374-6048 Fax 1-412-374-6168 SCHENECTADY OFFICE General Electric Building 33, Room 202A One River Road Schenectady, NY 12345, U.S.A. Tel 1-518-385-5218, 2629 Fax 1-518-385-4984 WINDSOR OFFICE 20 International Drive Windsor, CT 06095, U.S.A. Tel 1-860-731-6479, 6482 Fax 1-860-731-6478 DOOSAN HEAVY INDUSTRIES JAPAN CORP. Mita Kokusai Building, Room 2410 1-4-28, Mita, Minato-gu, Tokyo 108-0073, Japan Tel 81-3-3452-5451~3 Fax 81-3-3452-5624 BANGKOK OFFICE M-Thai Tower, 10th Floor All Seasons Place, 87 Wireless Road Phatumwan, Bangkok 10330, Thailand Tel 66-2-654-0690, 2 Fax 66-2-654-0693 BEIJING OFFICE Gateway Plaza, Tower B, 19th Floor No. 18 Xiaguangli, North Road, East Third Ring, Chaoyang District, Beijing 100027, China Tel 86-10-8454-7131, 7133 Fax 86-10-8484-7139 HANOI OFFICE Daeha Business Center, #1101 360 Kim Ma Street Ba Dinh District, Hanoi, Vietnam Tel 84-4-823-2501, 5 Fax 84-4-843-2302 HYDERABAD OFFICE White House, #119, Block 3 6-3-1192/1/1, Kundan Bagh Begumpet Hyderabad 500 016, India Tel 91-40-6613-2444/5 Fax 91-40-6613-2447 KOLKATA OFFICE Trinity Building, 3G 226/1 AJC Bose Road Kolkata 700 020, India Tel 91-33-4003-3018 Fax 91-33-2289-0576 MUMBAI OFFICE Maker Chambers-V, 1109~1110 Nariman Point, Mumbai 400 021, India Tel 91-22-2202-6504 Fax 91-22-2202-6557 NEW DELHI OFFICE Lotus Towers 2A, Community Centre New Friends Colony New Delhi 110 065, India Tel 91-11-5132-8031 Fax 91-11-5132-8039 SHANGHAI OFFICE City Center of Shanghai, Room 2802, 100 Zunyi Road, Changning District Shanghai 200051, China Tel 86-21-6237-2485~6 Fax 86-21-6237-2487 TAIPEI OFFICE 51 Keelung Road, Room 704 Section 2, Taipei, Taiwan, R.O.C. Tel 886-2-2739-2255(ARS) Fax 886-2-2739-2266 FRANKFURT OFFICE Arabella Center, 9th Floor Lyoner Strasse 44-48 Frankfurt am Main 60528, Germany Tel 49-69-69-5004-0 Fax 49-69-69-5004-10 ABU DHABI OFFICE P.O. Box 27767 Al Ghaith Tower, Suite 508 Hamdan Street, Abu Dhabi, U.A.E. Tel 971-2-627-6273 Fax 971-2-627-6274 DUBAI OFFICE P.O. Box 11859 Al Serkal Building, Office No. 308 Airport Road, Dubai, U.A.E. Tel 971-4-294-4699 Fax 971-4-294-9930 KUWAIT OFFICE Villa 15, Street 24, Block 4 Sabah Al-Salem Area, Kuwait Tel 965-551-8436 Fax 965-551-8453 RIYADH OFFICE P.O. Box 9656 Riyadh 11423, Saudi Arabia Tel 966-1-419-1920, 1696 Fax 966-1-419-1995 TRIPOLI OFFICE P.O. Box No. 7780 Tripoli, Libya Tel 218?21?360?8451 Fax 218-21-361-0563 DOOSAN WATER R&D CENTER Gold & Diamond Park Building No. 6, Office 112 Sheikh Zayed Road P.O. Box 282350, Dubai, U.A.E. Tel 971-4-347-7051 Fax 971-4-347-7142 DOOSAN HYDRO TECHNOLOGY, INC. 912 Chad Lane Tampa, FL 33619 , U.S.A. Tel 1-813-549-0182 Fax 1-813-549-0183 DOOSAN HF CONTROLS CORP. 1624 West Crosby Road, Suite 124 Carrollton, Texas 75006, U.S.A. Tel 1-469-568-6526, 6557 Fax 1-469-568-6589 DOOSAN IMGB 104 Berceni Road Bucharest 4, Romania Tel 40-21-301-2602 Fax 40-21-301-2701 DOOSAN BABCOCK ENGINEERING & SERVICES INDIA PVT. LTD. DLF Building No. 8, 3rd Floor DLF Cyber City Phase II Gurgaon 122 002, Haryana, India Tel 91-124-439-8200 Fax 91-124-414-7006 DOOSAN PROJECTS INDIA PVT. LTD. 322 Solitaire Corporate Park, Chakala Andheri Kurla Road, Andheri (East) Mumbai 400 093, India Tel 91-22-4097-0500 Fax 91-22-4097-0599 DOOSAN HEAVY INDUSTRIES VIETNAM CO., LTD. [DOOSAN VINA] No. 1 An Duong Vuong Street Quangngai City, Quangngai Province Vietnam Tel 84-55-713-001~7 Fax 84-55-713-008 HAN-VIET HEAVY INDUSTRY & CONSTRUCTION CORP. [HANVICO] 933 Ton Duc Thang Street Hong Bang District, Hai Phong, Vietnam Tel 84-31-371-2720 Fax 84-31-712-714~5 CEYLON HEAVY INDUSTRIES & CONSTRUCTION CO., LTD. [CHICO] Oruwala Athurugiriya, Sri Lanka Tel 94-114-440031~2 Fax 94-114-440030 HANJUNG POWER LTD. P.O. Box 2803, Boroko, NCD Port Moresby, Papua New Guinea Tel 675-320-0529 Fax 675-321-2984

Overseas Subsidiaries
DOOSAN BABCOCK ENERGY LTD. 11 The Boulevard, Crawley West Sussex, RH10 1UX, U.K. Tel 44-1293-612-888 Fax 44-1293-584-816

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www.doosanheavy.com

SEOUL OFFICE
1303-22, Seocho-Dong, Seocho-Gu. Seoul 137-920, Korea (C.P.O Box 1826, Seoul Korea) Tel. 82-2-513-6114, Fax. 82-2-513-6200

HEAD OFFICE AND CHANGWON PLANT

555, Guigok-dong, Changwon, Gyeongsangnam-do, 641-792, Korea Tel. 82-55-278-6114, 7114 Fax. 82-55-264-5551,5552