Emmenbrücke / Witten Dezember 2024 – The Swiss Steel Group, a leading provider of specialty steels, has unveiled its new hot-work tool steel, E 40 K, designed specifically for high-performance die-casting molds. This innovative material offers improved resistance to thermally induced cracking, significantly extending tool life and reducing maintenance intervals. With its high precision and efficiency, E 40 K sets new standards, particularly in the automotive industry and other sectors with demanding requirements.
Challenges in Die Casting: Thermal Stress and Wear
The die-casting process subjects molds to extreme thermal stress as molten metals are injected under high pressure and undergo cyclical temperature changes. These conditions often cause thermal stresses and surface cracking, which reduce part quality and mold lifespan, leading to costly tool replacements and production downtimes.
The automotive industry, in particular, demands materials that can withstand these stresses, ensuring reliable and efficient production of complex, large-scale die-cast components.
Innovative Material Solutions: Focus on Crack Resistance and High-Temperature Strength
Swiss Steel Group’s new hot-work steel, E 40 K, features a precisely balanced combination of high-temperature strength and toughness. These properties minimize crack formation and significantly slow its progression.
Scientific testing has demonstrated that E 40 K achieves a substantially higher yield strength and tensile strength at temperatures ranging from 550°C to 650°C compared to conventional materials such as 2343, 2344, and 2367. This makes the alloy particularly suitable for high-temperature applications where durability and wear resistance are critical.
Experimental Validation: Outstanding Resistance to Thermal Cracking
E 40 K underwent rigorous simulated thermal cycling tests to evaluate its resistance to cracking. Samples were heated to 650°C and quenched in water to replicate real-world production conditions.
After 8,000 cycles, E 40 K exhibited an average crack depth reduction of 10 mm compared to conventional materials. Microscopic analyses confirmed slower crack propagation, highlighting the technical superiority of this new material.
Field Experience: Improved Lifespan and Cost Efficiency
Field trials confirmed the exceptional performance of E 40 K in various applications:
- Zamak Alloy Automotive Keychains in Brazil: Mold lifespan increased from 300,000 to 700,000 cycles, achieving a productivity gain of 233%.
- Automotive Water Pumps: Mold lifespan improved from 100,000 cycles with conventional materials to 150,000 cycles with E 40 K, representing a 50% improvement.
- Streetlight Modules: A lighting industry customer achieved the target of 200,000 cycles for the first time, compared to approximately 130,000 cycles with previous materials.
Efficiency and Reliability for Demanding Applications
With its optimized hot-work tool steel, E 40 K, the Swiss Steel Group offers a solution that extends the lifespan of die-casting molds, maintains consistent surface quality, and reduces operating costs. These advancements contribute to fewer maintenance intervals and enhanced efficiency in industrial manufacturing processes. Additionally, E 40 K is available in a Green Steel version, produced with a reduced carbon footprint, aligning with the company’s commitment to sustainability.
By introducing this innovative and sustainable material, the Swiss Steel Group reinforces its position as a forward-thinking partner for high-performance production, addressing the challenges of modern industries with cutting-edge material solutions.
Über Swiss Steel Group
Swiss Steel Group mit Hauptsitz in Luzern (Schweiz) gehört zu den weltweit führenden Produzenten von Spezialstahl-Langprodukten. Dank des ausschliesslichen Einsatzes von Stahlschrott in Elektrolichtbogenöfen zählt die Gruppe zu den europaweit relevantesten Unternehmen in der Kreislaufwirtschaft und ist im Bereich nachhaltig produziertem Stahl – Green Steel – unter den Marktführern. Swiss Steel Group verfügt über eigene Produktions- und Distributionsgesellschaften in über 30 Ländern und bietet über ihre starke Präsenz vor Ort eine breite Palette individueller Lösungen in den Bereichen Edelbaustahl, rostfreiem Stahl und Werkzeugstahl an. Swiss Steel Group ist an der SIX Swiss Exchange kotiert, erwirtschaftete einen Umsatz von rund EUR 3.2 Mrd. im Jahr 2023 und verfügt über eine Belegschaft von rund 8’800 Mitarbeitenden.
The post Swiss Steel Group Introduces Optimized Hot-Work Tool Steel E 40 K: Extended Lifespan, Enhanced Surface Quality, and Reduced Operating Costs for Die-Casting Molds first appeared on Informed Infrastructure.
