Special Quality Die Steel & Heat Treatment Acceptance Criteria for Die Casting Dies Sse eee eter TN Ve DIE WELDING“Although great cate has been taken to provide accurate and current information, nether the authors) ‘nor the publisher, nor anyone else associated with this publication, shall be lable for any loss darmage ‘or liability directly or indirectly cased or alleged tobe eased by this book. The material contained herein isnot intended to provide specific advice or recommendations for any specific situation. “Any opinions expressed bythe suthor(e) ae not necessxily those of NADCA, “Tradcmatk notice: Product or corporate names may be trademarks or reystered trademarks and are wsed ification and explanation without inte to infinge nor endorse the proctor corporation. only f (© 2018 by North American Die Casting Asodation, Artingwon Heights Mlinois, All Rights Reserved. [Neither this hook nor any parts may be reproduced or transmitted in any frm or by any mean, cleetonie or mechanical, nclding photocopying, microfilming, and recording o by any information ‘ora and retrieval system, without permission in writing from the publishes.Special Quality Die Steel & Heat Treatment Acceptance Criteria for Die Casting Dies NADCA #207-2018 Contents Abstract 1 Statement of Purpose 1 I. Material Quality Requirements 2 Il. Material Quality Certification of Conformance 5 TIL Heat Treatment Quality Requirements, 6 IV. Heat Treatment Quality Testing Requirements 8 V. Heat Treatment Quality Certification of Conformance 10 Acknowledgements 13 ‘Appendix I: Guide to Sample Preparation Techniques 15 Appendix 2: Practical Guide to Stee! & Heat Treatment Quality 19 Appendix 3: Welding Die Casting Dic Materials 31 Appendix 4: Non-Ferric Materials 33 Cross Reference Guide to Special Quality Die Steel 4 Grades & Categories by: NADCA DIE MATERIALS COMMITTEE, [ASTM Standards referred to in this document may be obtained from: [ASTM Sales Department + 100 Barr Harbor Drive + West Conshohocken, PA 19428 Phone 610.832.9500 Die Stel Acceptance and Heat Treat Criteria —2018 =ii 10 13 20 20 34 ind Addition: ‘Comment Change 2016 to 2018 ‘Changed #207-2016 to #207-2018, Change Copyright © 2016 to Copyright © 2018 Added reference to Grades B-H, Change NADCA #207-2016 to NADCA #207-2018 Added Grade H, Type 2367 Modified - Low Mo, to Table 1. C 0.33 - 0.38, Mn 0.20 - 0.50, P.0.015 max, S 0.003 max, $i 0.10 ~ 0.40, Cr 4.50 5.20, Mo 1.60 - 2.00, V 0.70 - 0.90. Changed the Mo range for Grade F from 1.00 ~ 1.50 to 1.00 - 1.60. Added reference to Grade H in the micro cleanliness section to Grades B-E & G-H. Change to “1, Austenitize at the designated hardening temperature for 30 ~ 45 minutes,” Added ref to Grade H, Was “A. NADCA Grade (A-G)’, now “A. NADCA Grade (A-H)” Add Grade H, H1885, 1885, 1030, 14,11,14,11 Updated the acknowledgements Change “Conformance to NADCA #207-2006 to Conformance to NADCA #207-2018” ‘Change Steel grade was “NADCA Grade (A-E) to NADCA Grade (A-H)” Change Kind TQI - Austinitizing temp from 1820(1010) to 1850(1010), Added Sanyo QDN- to Grade F. F 1885, 930-1200 (500-650) , 1470-1560(800-850), 1885(1030) , Added Kind HPI to Grade E, £1885, 1020-1200(550-650), 1500-1560 (815-850), 1885(1030), Added Grade H. Added Schmoltz & Bickenbach Thermodur E 40 K Superclean to Grade H, 11885, 1020-1180(550-640), 1550-1580(845-860), 1885(1030). Changed Date of List to 2018 Changed date of list to 09/2018 Changed 2016 to 2018 in the footer iv Die Stet Acceptance and He reat Criteria 2018Abstract ‘An agreement has been reached with NADCA member firms that are major material suppliers and/or heat treaters of die steel to the die casting industry. Acceptance criteria, restrictive specifications as noted, and a certification plan have been developed for both the Material Quality and the Heat Treatment Quality of Special Quality die steels. By specifying die stecls produced to these specifications, improved levels of| cleanliness, a reduction in micro and macro banding, and impact toughness capabilities ae certified. These steels will respond more uniformly and predictably to heat treatment, thus reducing the risk of excessive distortion and cracking during heat treatment and giving longer and more consistent die life. With the exception of Grade A die stel (Premium H13) and Grade F and where noted herein the stee! making process shall include secondary refining, either ESR (electro-slag remelt) or VAR (vacuum are remelt). However, small round stock less than 3” diameter may not be available by these remelt processes. Regardless of the steel making process or the forging practices all material covered by this specification must meet the quality requirements in this specification, ‘The heat treatment quality requirements inthis specification pertain to the vacuum hardening and high-pressure ‘gas quenching process. While NADCA recognizes the viability of other heat treatment methods, the scope of| the procedures within this specification are exclusively vacuum austenitizing and pressurized gas quenching. Statement of Purpos ‘These acceptance criteria and specifications are not intended forall die casting applications. They apply ‘where high volume production or critical performance is required. Die casters and too! builders should insist that certification of the Material Quality accompany each piece of Special Quality die steel purchased for use indie casting dies and that certification of the Heat Treatment Quality accompany each furnace load of Special Quality die stee! hardened in accordance with this protocol For applications requiring a high level of Material Quality and Heat Treatment Quality, a variety of ‘commercially available Special Quality die steels are listed inthis specification, designated as Grades B~H, Class 1 of 2, and should meet the appropriate specification requirements of NADCA #207-2018, For applications requiring a lessor level of Material Quality and/or Heat Treatment Quality, Premium H13 dic steel is available and should meet the specification requirements of NADCA #207-2018 as Grade A, Class 1 or 2. Ie should be noted that die performance is a complex combination of many factors including die size, die design, casting alloy, operational procedures, steel composition, austenitizing temperature, impact toughness and hardness. Other factors such as temper resistance, hot strength, and fatigue res also effect die performance and should be considered when specifying steel grade and heat treatment parameters. Final hardness should be selected based upon stecl grade, size, and die design. Consult your steel supplier and/or heat treater for guidance. NOTE: Every effort has been made to assure information contained in these procedures is correct. However, NADCA does not accept responsibility for damage, injury or costs incurred by using these procedures. ‘Check the suppliers" instructions for specific directions on products used. Be sure to comply with all applicable safety codes and regulations. For non-ferrous materials, See Appendix 4, Die Stel Acceptance and Heat Treat Criteria —2018 +1nts ‘A. Chemical composition (% by weight) of Critical Alloying Elements & Impurities Special Quality grades of die ste! shall conform to the Chemical Requirements of Table | Material Category Tels See Tale I~ Chemical Composition of Special Quality Die Steels B. Hardness Both Premium and Superior Qualities: Annealed hardness, as received, shall not exceed 235 HBW. C. Microcleanliness ‘The permissible limits of microcleanliness (severity levels of non metallic inclusion content shall be determined by ASTM E45, Method A (latest revision). Plate I-r should be used to obtain rating increments of 05. ‘The maximum allowable limits are as follows: GRADE A&F. GRADES B-E& G-H INCLUSION TYPE THIN HEAVY THIN HEAVY A Gulf) 10 0s 05 05 B (aluminide) 15 10 15, 10. (C Galicate) 10 10 05, 05 D (globular oxides) 20 10, 15, 10 D. Ultrasonic quality (ASTM A681 S1.1) Appropriate ultrasonic inspection techniques shall be performed to assure soundness. All blocks shall be free from internal defects such as stringers, oxides, porosity, bursts, heavy segregation, etc. as indicated by ultrasonic testing. Ultrasonic examination of the original stel stock shall be conducted in accordance with ASTM recommended practices A388 and E114 (latest revision). Acceptance criteria are as agreed upon between supplier and vendor, 2+ Die Stat Acceptance and Heat Treat Criteria — 2018E. Impact Capability Testing ‘Impact capability testing pertains to all mill product forms with a thickness greater or equal to 2-1/2 inches. ‘Specimen blanks shall be removed from the short transverse orientation corresponding tothe center location ‘of the parent block of steel (se Fig, | and 2). A minimum of one set of 5 impact specimens shall be tested per lot of material produced. A lot shall consist ofall the product ofa single ingot, which is forged or rolled via a ‘common procedure to one size and annealed in a single furnace charge. Multiple starting ingots, variations in forging or rolling size or procedure, or variations in annealing furnace charge are defined as a multiple lots and shall require additional sets of tests. Fig. 1 Sohemane diagram illustrating the removal of capabity Charpy V-notch pecimens from the short transverse “orientation corresponding tothe center location ofa parent Block of sel that has rectangular square cross-section Fig, 2 Schematic diagram iustraning the removal of capability Charpy Vometch specimens from the transverse (radial) orientation correspnding tothe center location of parent har of tee! hat has aeirealareros-section NOTE: The base of the notch shall be parallel to the longitudinal direction of the parent bar. See Charpy V-notch samples per ASTM A370-05, Fig. Ha. NOTE: Specimens must be marked in such a way as o maintain the proper orientation of the Charpy specimens to insure that the proper face is notched. Die Stel Acceptance and Heat Treat Criteria — 2018 +3,Individual specimens shall be machined oversize to be nominally 1/2" x 1/2" x 2-1/2"each. Sufficient aversize stock allowance must be made to insure freedom from decarburization after final machining. Specimens are to bbe hardened and tempered before machining to final dimensions. ‘See Table 2 for designated austentizing temperatures. ‘Specimens shall be heat trated, machined, and tested as follows: I. Austenitize atthe designated hardening temperature for 30 — 45 minutes; 2. Oil quench. Oil temperature 120°F (50°C) maximum; 3. Minimum double temper at a temperature of at least 1100°F (590°C) for 2 hours minimum each temper to achieve a final hardness of 44/46 HRC; Air cool to room temperature between each temper; ‘5. Following the preceding laboratory hardening process, the samples shall be machined to final size and finish ground. See Charpy fullsize test impact specimen per ASTM A370, Fig, Ha: + adjacent sides shall be at 90 degrees +10 minutes + eros section dimensions shall be +0.100 mm (40.004 in), + Tength of specimen shall be 55-41 mm (2.165 + 0.040 in}, + Surface finish shall be 63 micro inch (1.6 micron) maximum on the 55 x 10 mm faces + After final machining, verify and record the final hardness of each sample (44/46 HRC) | Nathienathiosdge sor Aajacet essa at 30 /-fomin Grosssncton dress #/-007S mm /-0003in) Length ofspecimen (40-25 mm (40,-0.100in) Centering ofnotch(2) H/T mm (+/"0039in) | ‘Angle of notch bys | Radius of notch 41-0025 mam (+/-0.001 in) | Notch depth 47-0025 ra +/-0.001 in) Fish requirements 2m (63m) on notched surface and opposite face; 4 ftm (125 la} von other two surfaces, = (Charpy fll sie test impact specimen per ASTM A370, Fig, Ha 7 K Five impact specimens shall be tested at room temperature on test machines that meet the calibration requirements of ASTM E23 or ISO 148/R442 (latest revision). Impact data should be read to the nearest 0.1 fi-b and recorded after rounding to the nearest whole number per ASTM A370-0S para. 25.4.1. The values of the highest and lowest specimens shall be discarded and the average of the remaining three results shall be computed. For the purpose ‘of conformance to this specification, report the average to the nearest 0.1 fe-lb and do not round the result. 7. See Table 2 for Steel Capability Impact Toughness Acceptance Criteria NOTE: Impact specimens are to be individually heat treated prior to final machining in accordance with the ‘method prescribed above and are to be notched only after hardening and final machining. Ground notches are preferred and shall be used for referee purposes. EDM notches are not allowed. 4+ DieSitcl Accaptan nd Heat Treat Criteria — 2018I F. Grain Size: Grain size shall be developed using the Direct Quench method per ASTM E112 by austenitizing atthe ‘designated hardening temperature for 30-45 minutes, quench at a moderate or rapid rate and temper at 1100°F (690°C) minimum. Hardening should be in a protective media or by using an appropriately oversize sample in a non-protective media. Grain size to be measured by using the ASTM comparative method and shall be predominately ASTM No. 7 or finer. An alternative method to rate the grain size may be used. The Shepherd fracture grain size shall be predominantly No. 7 or finer when made on a hardened specimen, air cooled after heating for 30 minutes at the appropriate austenitizing temperature in a protective media (or using an appropriately oversize sample in a non protective media) and untempered, G. Annealed Microstructure: ‘The annealed microstructure ofthe as-received steel shall consist essentially ofa feritic matrix with a homogeneous distribution of spheriodized carbides when examined at 5OOX, after being polished and etched ‘with 596 Nital. Acceptable microstructures for annealed die steels steel are shown in the NADCA Annealed Microstructure Reference Chart. H: Banding Segregation: ‘The annealed microstructure shall be free of excessive banding by conformance with the NADCA Ban ‘Segregation Reference Chart for levels of mierobanding or microchemical segregation. For sizes 4” and below, banding segregation shall not be cause for rejection unless excessive primary carbides are present. ri if Conformance Material that has been ‘A. NADCA Grade (A-H) designated as NADCA |B, Annealed Brinell Hardness ie steet in accordance with this olen ena sal be D. Microcleantiness levels amanied Fa E, Confirmation of Acceptable Ultrasonie Inspection Certificate of Conformance F, Grain Size Number from the steel supplier that G_ Annealed Microstructure Rating Number includes the following data 44 sticrobanding Designation Levels and information: ee 1. Impact capability test results: shall include thee individual results of specimens and average result, heat treatment and final hardness. Note: The laboratory capability austenitizing temperature must be stated. J. Melt Practice: state whether the steel is air melt or secondary refined by VAR, ESR, or by an alternate method. Die Stel Acceptance and Heat Treat Criteria — 2018 +5I. Heat Treatment Quality Requirements Vacuum Heat Treatment Process Requirements ‘The most critical parameters in the heat treatment of Special Quality die steels are the austenitizing treatment and the quench rate from the austenitizing temperature, The quench rate must be rapid yet controlled to provide optimum metallurgical properties while minimizing distortion and the risk of cracking. A more detailed discussion of the heat treatment process is included in Appendix 2: Practical Guide to Steel and Heat Treatment Quality NOTE: ALL Special Quality Die Steels can be certified as ether “Class 1” or “Class 2” Heat Treatment Quality. Certification as Class I Heat Treatment Quality requires that, in addition to meeting all Cass 2 requirements, the material must meet a minimum impact toughness limi using a test coupon attached 0 the workplece prior to hardening. See Section WW-L for details. A. Equipment + Vacuum furnace with sufficient cooling capability to cool die surface from the designated austenitizing temperature (see Table 2 on page 10) at a minimum rate of $0°F/minute (28C/minute) + Furnace must have a programmable controller linked to multiple toad thermocouples. ‘+ Furnace must be capable of isothermal hold during quench based on input from surface and core thermocouples where interrupted quench is required B, Furnace Loading + Pieces inthe load shall be placed and distributed to allow for uniform heating and quenching. + ‘The geometry ofthe pieces must be considered to insure uniform heat treatment and crack prevention. + ‘The furnace must not be overloaded, so that the minimum quench rate can be achieved. C. Thermocouple Placement + A dedicated thermocouple hole for placement ofthe surface thermocouple (T.) is recommended. Hole should typically be V8" to 1/4" G.175mm to 6.35mm) diameter, depending on thermocouple wire used and should be 0.625" = 0.125" (15.87mm + 3.175mm) deep. + The surface thermocouple (T,) hole should be located inthe center ofthe largest area ofthe di backside and shouldbe at least 1 x 1/4W or mid-radis from the nearest corner + ‘The core thermocouple (T.) should be placed as close othe center of mass as possible using existing coolant holes. In easés where core thermocouple placement is not possible, the furnace load shall be controlled from a load block that represents the maximum thickness of the die witha thermocouple at the center of mass, + All thermocouple hols shall be packed wih a fiber refractory material to prevent direct contact with quenchant. + Thermocouple wires must be secured to prevent movement during quenching + multiple blocks are hardened in the same load, thermocouples shouldbe placed inthe block with the largest ross section. the D. Preheating Practice + Load work into cold furnace and heat ata rate not to exceed 400°F/hour (220°C/hour) as measured by T, + Heat the Ist designated Preheat temperature in Table 2 and hold until T,<200°F (110°C). + Heat tothe 2nd designated Preheat temnperature in Table 2 and hold until T, -T, < 25°F (14°C). ‘+ Additional preheating steps may be used atthe discretion of the heat treater or toolmaker. {6+ Die Stet Acceptance and Heat Treat Criteria — 2018,