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1. INTRODUCTION
Hot forging is one of the oldest metal-forming
processes used in the production of the critical parts for
various industrial purposes. As a process, forging can
be characterized by good mechanical properties of the
workpiece, a short production time, high productivity
and optimal material utilization. These advantages are
achieved normally for rather large production
quantities, because of the high costs of tooling as well
as the long set-up times for production line [1]. The
dies lifetime is a very important factor determining
production cost and rate [2, 3]. Thus, optimizing dies to
achieve longer lifetime and cheaper production cost is
always desirable in these industries.
Post-heat
temp.
Heat
input
12 V,
100 A
370 C
1.2 m/s
560 C
400
J/mm
Preheating
temperature
Forging
temperature
Lubricant
250-320 C
1050 C
Graphite-Oil
Press type
Press capacity
Mechanical
620 tons
Workpiece
material
EN3C
T2
Welding
velocity
H11
Pre-heat
temp.
2. EXPERIMENTAL
Alloy
Voltage &
Current
Composition (wt %)
C 0.38%, Cr 5%, Mo 1.5%, V .5%, Fe
bal.
C 0.9%, Cr 4.5%, W 18%, V 2%, Fe bal.
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(b)
Figure 2. Weld overlay microstructure before the wear
test.
Microhardness (HV)
650
3.1.2 Hardness
600
550
500
450
400
350
300
650
600
550
500
450
400
350
300
0
0.1
0.2
0.3
0.4
0.5
0.6
0.5
0.6
(a)
Microhardness (HV)
650
600
550
500
450
400
350
300
0
(a)
0.1
0.2
0.3
0.4
(b)
Figure 5. Microhardness profiles in hardfaced pins
after the wear test at: a) room temperature and b)
550C.
214
25
H11 pins
Hardfaced pins
20
15
10
0
25
400
550
3.3 Dies
(c)
Figure 9. Surface cracks in H11 die after service: a)
propagation; b) coalescence and c) propagation parallel
to the surface.
3.3.1.2 Hardness
The hardness profile from the surface to the depth of an
H11 die is shown in figure 10. As can be seen, a very
hard layer has been formed at the surface, and just
beneath of this layer, the hardness falls into a very low
level. Retained austenite and annealed structure of the
sublayers are responsible for this low hardness. At
more depths from the surface, the hardness rises to its
primal level.
(a)
(b)
(a)
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3.3.2.2 Hardness
The hardness profile for the hardfaced die after the
service is shown in figure 13. The hardness of the
surface layer is high because of the mentioned
recrystallized structure and carbides precipitation on
the grains internal defects. The main difference with
that of the H11 die is the absence of the soft sublayer
beneath the hard surface layer.
3.3.3 Comparison of the dies performance
Dimensions of both dies were controlled during the
service. Results of these controls are shown in figure
14. The hardfaced die has lost only about 0.25 mm of
its dimensions after about 16000 blows, while the H11
die has lost about 2.25 mm of its dimensions after
about 4000 blows.
(b)
Figure 11. Microstructure of the hard-faced die after
service: a) far from the surface and b) near the surface.
3.3.2 Hardfaced die
600
Microhardness (HV)
3.3.2.1 Metallography
The microstructure of two different regions of the weld
overlay is shown in figure 11. As can be seen, far from
the surface, the structure contains dendrites, primary
carbides, some precipitated carbides on the grain
boundaries. But close to the die surface, a
recrystallized structure including the precipitated
carbides in regular lines inside the grains and grain
boundaries, and primary carbides could be
distinguished. This indicates that the deformation at a
sufficiently high temperature for recrystallization has
occurred. Regular lines are the stacking faults or other
planar defects in the crystal structure which are
decorated by the carbides precipitation. The arrow on
the micrograph shows a thermal twin. Determining the
defects type is beyond our discussions in the current
study.
500
400
300
200
100
0
2.5
Hardfaced Die
H11 Die
1.5
1
0.5
0
0
3000
6000
9000
12000
15000
18000
Number of blows
Acknowledgements
The authors wish to thank MOHAM Industries for their
kind cooperation and supports.
References
1.
4. CONCLUSIONS
The results of this study can be summarized as follow:
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