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Alloy Tool Steel

Overview

Alloy tool steel is a specialized category of steel that is enhanced with the addition of alloying elements such as chromium (Cr), molybdenum (Mo), tungsten (W), and vanadium (V). These elements significantly improve the steel’s hardenability, toughness, wear resistance, and heat resistance, making alloy tool steel an essential material in various high-performance applications. This type of steel is primarily used in the manufacturing of measuring tools, cutting tools, impact-resistant tools, and both cold and hot molds, as well as specific tools for unique applications.

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Characteristics

Enhanced Hardenability: The addition of elements like chromium and manganese improves the hardenability of the steel, allowing for deeper and more uniform hardening.
Improved Toughness: Alloying elements such as vanadium and molybdenum enhance the toughness, making the steel resistant to cracking and breaking under stress.
Wear Resistance: Tungsten and chromium increase the wear resistance, extending the life of tools made from this steel.
Heat Resistance: The alloy composition provides excellent performance at high temperatures, crucial for hot working applications.
Versatility: Depending on the required properties, different alloying elements can be selectively added to create a wide range of alloy tool steels suited for specific tasks.

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Production Process

Material Selection: The process begins with the selection of high-quality raw materials, including various alloying elements.
Melting: These materials are melted together in an electric arc furnace (EAF) to create a homogeneous molten alloy.
Casting: The molten steel is then cast into ingots or continuous cast into billets.
Forging/Rolling: The ingots or billets are hot-forged or rolled to the desired shape and size, which improves the steel’s grain structure.
Heat Treatment: A critical step where the steel undergoes precise heating and cooling cycles to achieve the desired mechanical properties. This may include processes like annealing, quenching, and tempering.
Finishing: The steel is then subjected to various finishing processes, such as machining and surface treatments, to meet the specific requirements of its intended application.

Applications

Cutting Tools: Alloy tool steel is ideal for making cutting tools like drills, saw blades, and milling cutters due to its high wear resistance and toughness.
Molds: Used extensively in the production of cold and hot molds for plastic injection molding, die-casting, and metal forging.
Measuring Tools: The precision and durability of alloy tool steel make it perfect for measuring tools such as gauges and micrometers.
Diesel Engine Components: Parts like pistons, valves, valve seats, and fuel injector nozzles benefit from the high strength and wear resistance of alloy tool steel.
Impact Tools: Tools that need to withstand heavy impacts, such as hammers and chisels, are often made from this steel to ensure long-lasting performance.

Practical Examples

Automotive Industry: Alloy tool steels are used to produce engine parts like camshafts and crankshafts that require high strength and fatigue resistance.
Aerospace: Components such as turbine blades and engine mounts, which operate under extreme conditions, are often made from specialized alloy tool steels.
Manufacturing: The production of precision cutting tools and molds for plastic and metal parts heavily relies on the superior qualities of alloy tool steel.

Common Sizes

1. Round Bars

Diameter Range: 10mm to 500mm
Length Range: 3000mm to 6000mm

2. Flat Bars

Thickness Range: 5mm to 200mm
Width Range: 20mm to 1000mm
Length Range: 2000mm to 6000mm

3. Square Bars

Side Range: 10mm to 300mm
Length Range: 3000mm to 6000mm

4. Plates

Thickness Range: 10mm to 400mm
Width Range: 1000mm to 2000mm
Length Range: 2000mm to 6000mm

5. Sheets

Thickness Range: 1mm to 6mm
Width Range: 500mm to 1500mm
Length Range: 1000mm to 3000mm

Chemical Composition

Alloy Tool Steel
NO.	Type	Grade	Chemical Composition (Mass Fraction) /%
			C	Si	Mn	P	S	Cr	W	Mo	V
			C	Si	Mn	≤		Cr	W	Mo	V
1-1	Gauge and Cutting Tool Steel	9SiCr	0.85~ 0.95	1.20~ 1.60	0.30~ 0.60	0.030	0.030	0.95~ 1.25
1-2		8MnSi	0.75~ 0.85	0.30~ 0.60	0.80~ 1.10	0.030	0.030
1-3		Cr06	1.30~ 1.45	≤0.40	≤0.40	0.030	0.030	0.50~ 0.70
1-4		Cr2	0.95~ 1.10	≤0.40	≤0.40	0.030	0.030	1.30~ 1.65
1-5		9Cr2	0.80~ 0.95	≤0.40	≤0.40	0.030	0.030	1.30~ 1.70
1-6		W	1.05~ 1.25	≤0.40	≤0.40	0.030	0.030	0.20~ 0.30	0.80~ 1.20
2-1	Impact- Resistant Tool Steel	4CrW2Si	0.35~ 0.45	0.80~ 1.10	≤0.40	0.030	0.030	1.00~ 1.30	2.00~ 2.50
2-2		5CrW2Si	0.45~ 0.55	0.50~ 0.80	≤0.40	0.030	0.030	1.00~ 1.30	2.00~ 2.50
2-3		6CrW2Si	0.55~ 0.65	0.50~ 0.80	≤0.40	0.030	0.030	1.10~ 1.30	2.20~ 2.70
2-4		6CrMnSi2Mol	0.50~ 0.65	0.75~ 2.25	0.60~ 1.00	0.030	0.030	0.10~ 0.50		0.20~ 1.35	0.15~ 0.35
2-5		5Cr3MniSiMoiV	0.45~ 0.55	0.20~ 1.00	0.20~ 0.90	0.030	0.030	3.00~ 3.50		1.30~ 1.80	≤0.35

Comparison Table of Steel Grades by Country

Alloy Tool Steel
NO.	GB	ASTM	JIS
1-1	9SiCr		SK7
1-6	W	F1	SK120
2-1	4CrW2Si		SKD11
2-2	5CrW2Si	S1
2-4	6CrMnSi2Mol	S5
2-5	5Cr3MniSiMoiV	S7