cast materials for automotive stamping dies
Post on 06-Apr-2016
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Darryl YoungDarryl YoungTechnical SpecialistTechnical Specialist
Advanced Die Materials and Die ManufactureAdvanced Die Materials and Die Manufacture
Ford Motor Company Dearborn USA
Cast Materials for Cast Materials for Automotive Stamping DiesAutomotive Stamping Dies
International Sourcing Issues
International SourcingDrivers
Pressure to Reduce Investment
Pressure to Reduce Lead Time
Purchasing Agent
“ I can get it cheaper and quicker by sourcing overseas”
“Die construction source quoted to our die standards”
Result
Plant Receives Strange Die
Purchasing Agents gets Promoted
Why Is it a Problem?
MaintenancePreventative Maintenance History?
Repair Welding Rod and Procedure?
Engineering ChangesMachining: Feeds, Speeds, Cutters?
Root CausesFoundries
Foundries reluctant to pour unfamiliar grades
Don’t want liability of a cracked casting
Root CausesIndustry Standards
US(NAMMS)Mechanical Properties, Microstructure, Chemistry and As-Cast Heat Treatment
Europe (EN)Mechanical Properties-IronChemical Composition-Steel
Japan (JIS)Mechanical Properties-IronNo Tooling Grade Cast Steel Specified
Root CausesIndustry Standards
EN 1563 Standard for Spheroidal Graphite Cast Irons states; “The Material shall be designated either by symbol or by numbering as given in Table 1, Table 2, Table 3 and Table 4”
EN-GJS-350-22 = EN-JS1010
Root CausesTooling Sources
Don’t want to work with unfamiliar grades
Substitute locally available materials
Claim the substitutions are equivalent
Root CausesToolmakers Don’t Change
GG25
Everybody makes itEverybody uses itNobody Specifies it
New Symbol is EN-GJL-250
Categories of Automotive Cast Die Materials
Gray Cast Iron
Nodular(Spheroidal/Ductile) Cast Iron
Cast Steel
Gray Cast Irons
Structural Materials Match up Well
G2500 (US) EN-GJL-250(Formally GG25) (Europe)FC300 (Japan)
Low StrengthLow Surface Hardening Response
Gray Cast Irons
G3500 (US)
Better Strength
Excellent Surface Hardening Response
No Direct Equivalents in Europe or Japan
Gray Cast Irons
G3500 (US)
Discuss with Foundry
310 MPa Tensile Strength/50 mm Cast-On Sample
Alloy with Chromium and Molybdenum
Nodular Cast Iron
Structural Materials Match up Well
D4512 (US) EN-GJS-450-10 (Europe)FCD450 (Japan)
Good Resistance to CrackingMedium StrengthLow Surface Hardening Response
Nodular Cast Iron
GGG70 is now EN-GJS-700-2U (Europe)
EN-GJS-700-2U similar to FCD 700-2 (Japan)
No US(NAMMS) Equivalent
Nodular Cast Iron
GGG70L
Buyer BewareNot an EN StandardL implies Ni, Cu, Mo
Surface Hardening Response
Nodular Cast Iron D6510 (US) Vs Japan/Europe 700 Grades
Lower Tensile Strength
Much Better Ductility
Chemical Composition and Microstructure Requirements
Cast Steels
US S0050A, Carmo, Cast Cut #1
Europe1.7140, 1.2320, 1.2333
JapanICD-5, SKD12
Cast SteelsCarmo(US) Vs 1.2333(Europe)
Match on Chemistry
PurchaserTramp ElementsHeat TreatmentMechanical Properties
Cast SteelsCast Cut #1(US) Vs 1.7140 a.k.a Fermo (Europe)
Very Close on Chemistry
Unauthorized/Unlicensed Foundries
Heat Treat/Mechanical Properties?Intellectual Property Issues?
Cast SteelsS0050A (US) Vs 1.7140, 1.2320 (Europe)
Easier to WeldSafer to CastLess Surface Hardening ResponseLess Wear Resistance
Cast SteelsJapan
Long Lead TimesTwo Popular Grades
ICD-5
SKD12
Cast SteelsICD-5
Proprietary name treated like Industry Standard
Originally a product of Hitachi Steel Co.
Reasonable Substitutes1.7140 (Fermo)Cast Cut #1
Cast SteelsSKD12
SKD12 SpecificationWrought MaterialBuyer Beware
Similar to 1.2363(Europe) & A2(US)
Cast SteelsSKD12
Considered Surface Hardenable?
ChallengingSurface HardeningCastingWeldingMachining
Cast SteelsNew Grades
Caldie-Uddeholm
GP4M-Dorrenberg
Currently Only Available in Europe
High Potential for AHSS Applications
Cast SteelsCaldie/GP4M
High Temper Resistance
Excellent Coating Substrate
Current Limitation
Physical Vapor Deposition (PVD) Chamber Size
Cast SteelsCaldie/GP4M
Reduced Cost Vs is 1.2379 Bar Stock Inserts
Less Machining
Less Chance of Breakage
Easier Welding
Equivalent Wear Resistance when Coated
Cast Materials for Cast Materials for Automotive Stamping DiesAutomotive Stamping Dies
International Sourcing Issues
Questions?
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