Time to read: 6 min
Delve into the world of tool steel, a critical material in the manufacturing sector, and explore its composition, manufacturing processes, and the diverse types that are essential for creating durable tools and machinery.
Tool steel is the resilient heart of the manufacturing industry, prized for its exceptional strength and durability. This category of carbon and alloy steels is specifically designed for crafting tools capable of shaping materials such as wood, plastic, and metals through various processes, including stamping and forming. From hand tools and drill bits to large-scale machine dies and plastic extruders, the applications of tool steel are extensive and diverse.
The hardness and toughness of tool steel are a result of its carbon content, which typically ranges from 0.7–1.5 wt%, with some variants containing between 0.2–2.1 wt%. While a higher carbon content enhances the steel's strength and hardenability, it also increases brittleness and weldability challenges. Cold-worked tool steels register around 60/62 HRC on the Rockwell C scale, with some reaching up to 66 HRC. These steels can withstand heat treatment, with specific temperatures contingent on their unique compositions.
Beyond carbon, tool steels incorporate additional elements to bolster strength and tailor properties for specific tool requirements. The inclusion of nickel or cobalt, for instance, bestows extra strength and resistance to high temperatures. Meanwhile, the addition of carbide formers, composed of iron-based alloys such as tungsten, vanadium, chromium, and molybdenum, enhances wear resistance.
Manufacturing Processes:
The production of tool steel primarily occurs through electric arc furnaces (EAF), though other methods exist. Here, we outline the key processes:
EAF: In this method, recycled steel scrap is melted and refined in a furnace, with alloying elements added to achieve the desired composition. Chemicals are introduced to minimize oxidation and purge impurities before the molten steel is poured into a ladle and cooled in ingot molds.
Electroslag Refining (ESR): This technique slowly melts the metal, resulting in a smooth and porous-free surface.
Powder Metallurgy: Metal powders are compacted and sintered to form a solid, dense material.
Annealing: To render steel more malleable and reduce brittleness, annealing alters its molecular structure through controlled heating and subsequent cooling.
Hot or Cold Drawing: Employed for the production of small or uniquely shaped tools with high tolerances, these processes require multiple passes at temperatures up to 1000°C for hot drawing, with cold drawing limited to a single, gentle pass to prevent breakage.
Types of Tool Steel Grades:
Tool steel grades vary in composition and characteristics, each suited for specific applications. For example, water-hardening (W) steel is utilized in the manufacture of bearings, clutch plates, rollers, wrenches, cams, and collets.
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