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SFM 
Spray formed steels 
The next generation high-performance tooling material 
Lauri Eklin 
SF Metals Ltd.
It is rare, that a new product enables as big cost savings and productivity 
improvements as spray forming steels do for t...
SFM 
Introduction 
 Spray formed steels are superior materials compared to conventionally 
produced cold working, hot wor...
SFM 
Introduction 
 Spray formed steels are superior materials compared to conventionally 
produced cold working, hot wor...
SFM 
Introduction 
 Spray formed steels are superior materials compared to conventionally 
produced cold working, hot wor...
SFM 
Introduction 
 Spray formed steels are superior materials compared to conventionally 
produced cold working, hot wor...
SFM 
Advantages of spray formed steels 
Technical/ 
product benefits 
Better processing properties (e.g. machinability) 
H...
SFM 
Advantages of spray formed steels 
Technical/ 
product benefits 
Better processing properties (e.g. machinability) 
H...
SFM 
Advantages of spray formed steels 
Technical/ 
product benefits 
Better processing properties (e.g. machinability) 
H...
SFM 
The Spray forming process 
 Melt is poured in an inert 
atmosphere and atomized in a 
high-speed gas flow (300 m/s) ...
SFM 
The Spray forming process 
 Melt is poured in an inert 
atmosphere and atomized in a 
high-speed gas flow (300 m/s) ...
SFM 
The Spray forming process 
 Melt is poured in an inert 
atmosphere and atomized in a 
high-speed gas flow (300 m/s) ...
SFM 
The Spray forming process 
 Melt is poured in an inert 
atmosphere and atomized in a 
high-speed gas flow (300 m/s) ...
Examples of the physical properties of spray formed steels 
M2 and M35 steels vs. SF steel of identicall composition 
SFM
Examples of the physical properties of spray formed steels 
M2 and M35 steels vs. SF steel of identicall composition 
SFM ...
SFM 
Example: D2 cold work steels 
 D2 steel is a high-chromium tool steel. It is especially favored in application 
wher...
H13 steel cast and annealed As spray formed 
SFM 
Hot working steels – example H13 
 H13 steels are hot working steels wi...
. 
SFM 
Applications 
Spray forming is an innovative method for manufacturing high-alloyed steels 
and other materials 
Sp...
. 
SFM 
Applications 
Spray forming is an innovative method for manufacturing high-alloyed steels 
and other materials 
Sp...
. 
SFM 
Applications 
Spray forming is an innovative method for manufacturing high-alloyed steels 
and other materials 
Sp...
. 
SFM 
Applications 
Spray forming is an innovative method for manufacturing high-alloyed steels 
and other materials 
Sp...
. 
SFM 
Applications 
Spray forming is an innovative method for manufacturing high-alloyed steels 
and other materials 
Sp...
. 
SFM 
Applications 
Spray forming is an innovative method for manufacturing high-alloyed steels 
and other materials 
Sp...
. 
SFM 
Applications 
... applications, such as 
Forging dies 
Metal extrusion 
High pressure die casting 
High-wear parts...
. 
SFM 
Applications 
... applications, such as 
Forging dies 
Metal extrusion 
High pressure die casting 
High-wear parts...
SFM 
Process steps of different steel production methods 
Powder Metallurgy Electroslag Remelting 
(ESR) Spray Forming 
Me...
SFM 
Process steps of different steel production methods 
Powder Metallurgy Electroslag Remelting 
(ESR) Spray Forming 
Me...
SFM 
Process steps of different steel production methods 
Powder Metallurgy Electroslag Remelting 
(ESR) Spray Forming 
Cl...
SFM 
Process steps of different steel production methods 
Powder Metallurgy Electroslag Remelting 
(ESR) Spray Forming 
Th...
Spray formed steel SFM2131 developed by SF Metals has provided its Fortune 
Global 500 customer in automotive industry wit...
The chief metallurgist of SF Metals, Dr. Y. YANG, inventor of the Precision Spray 
Forming (PSF) rapid tooling and manufac...
The chief metallurgist of SF Metals, Dr. Y. YANG, inventor of the Precision Spray 
Forming (PSF) rapid tooling and manufac...
SFM 
SF Metals 
 SF Metals employs about 10 highly-skilled people engaged in running the 
plant, R&D, engineering and sal...
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The properties and benefits of spray formed steels

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This presentation is about spray formed steels, which are superior materials compared to conventionally produced high-alloyed, high grade steels.

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The properties and benefits of spray formed steels

  1. 1. SFM Spray formed steels The next generation high-performance tooling material Lauri Eklin SF Metals Ltd.
  2. 2. It is rare, that a new product enables as big cost savings and productivity improvements as spray forming steels do for tooling materials. Even better, these improvements come with no cost of change. Usually, some production trials is enough for the supplier to fine tune the correct alloying and heat treatment. By switching to spray formed steels you can reduce your tooling or wearing part costs by 50%, or more. SFM _____________________________ Nykyään vain harvoin tulee vastaan tuote, joka mahdollistaa sellaiset säästöt ja tuottavuudenparannukset työkalu- ja kulutusosissa kuin spray forming -teräkset. Nämä edut voidaan hyödyntää varsin helposti ja ilman kalliita lisäinvestointeja. Käytännössä tarvitaan vain muutama tuotantokoe asiakkaan prosessissa/laitteessa, jotta toimittaja voi hienosäätää seostuksen ja lämpökäsittelyn teräkselle. Työkalu- ja kulutusosien kustannuksissa on mahdollista säästää jopa 50% tai enemmän.
  3. 3. SFM Introduction  Spray formed steels are superior materials compared to conventionally produced cold working, hot working and high speed steels – Strength, hardness, thermal and wear resistance
  4. 4. SFM Introduction  Spray formed steels are superior materials compared to conventionally produced cold working, hot working and high speed steels – Strength, hardness, thermal and wear resistance  The most obvious application areas are: – Forging, extrusion and die casting dies – High wear toolings/components in mining and construction, metals processing and other process industries – Other tools/tooling manufacture
  5. 5. SFM Introduction  Spray formed steels are superior materials compared to conventionally produced cold working, hot working and high speed steels – Strength, hardness, thermal and wear resistance  The most obvious application areas are: – Forging, extrusion and die casting dies – High wear toolings/components in mining and construction, metals processing and other process industries – Other tools/tooling manufacture  Lifetimes of componenta made from SF steels are usually double, or higher, compared to conventionally produced high grade steels
  6. 6. SFM Introduction  Spray formed steels are superior materials compared to conventionally produced cold working, hot working and high speed steels – Strength, hardness, thermal and wear resistance  The most obvious application areas are: – Forging, extrusion and die casting dies – High wear toolings/components in mining and construction, metals processing and other process industries – Other tools/tooling manufacture  Lifetimes of componenta made from SF steels are usually double, or higher, compared to conventionally produced high grade steels  In many applications SF steels perform equally to powder metallurgically produced steels
  7. 7. SFM Advantages of spray formed steels Technical/ product benefits Better processing properties (e.g. machinability) Higher process / production up-time (when used as a process component, e.g. in materials handling, drilling, etc.) More competetive end-product (weight reduction, performance via durability, lower cost, etc). Procurement costs When replacing hard metal or powder metal part w/ SF steel (200% to 400% cost saving) Weight reduction → less material needed Lifetime benefits (toolings) 2 x forging dies, HPDC dies 3 x cold extrusion ram, thread rolling die
  8. 8. SFM Advantages of spray formed steels Technical/ product benefits Better processing properties (e.g. machinability) Higher process / production up-time (when used as a process component, e.g. in materials handling, drilling, etc.) More competetive end-product (weight reduction, performance via durability, lower cost, etc). Procurement costs When replacing hard metal or powder metal part w/ SF steel (200% to 400% cost saving) Weight reduction → less material needed Lifetime benefits (toolings) 2 x forging dies, HPDC dies 3 x cold extrusion ram, thread rolling die Overall benefits -50% TCO and up to -80% TCO reported
  9. 9. SFM Advantages of spray formed steels Technical/ product benefits Better processing properties (e.g. machinability) Higher process / production up-time (when used as a process component, e.g. in materials handling, drilling, etc.) More competetive end-product (weight reduction, performance via durability, lower cost, etc). Procurement costs When replacing hard metal or powder metal part w/ SF steel (200% to 400% cost saving) Weight reduction → less material needed Lifetime benefits (toolings) 2 x forging dies, HPDC dies 3 x cold extrusion ram, thread rolling die Overall benefits -50% TCO and up to -80% TCO reported As a principle, if the anticipated benefits are not in the range of ”double lifetime” or similar significant productivity improvement, SF Metals will clearly communicate this to the customer. We believe strongly in win-win cases, only
  10. 10. SFM The Spray forming process  Melt is poured in an inert atmosphere and atomized in a high-speed gas flow (300 m/s) into droplets the size of 10- 200 μm
  11. 11. SFM The Spray forming process  Melt is poured in an inert atmosphere and atomized in a high-speed gas flow (300 m/s) into droplets the size of 10- 200 μm  The droplets undergo rapid solidification ( > 1,000 K/s), which results in an ultrafine grain structure, minimum segregation and an excellent carbide morphology
  12. 12. SFM The Spray forming process  Melt is poured in an inert atmosphere and atomized in a high-speed gas flow (300 m/s) into droplets the size of 10- 200 μm  The droplets undergo rapid solidification ( > 1,000 K/s), which results in an ultrafine grain structure, minimum segregation and an excellent carbide morphology  Melt droplets are targeted to solidify in the form of a billet.
  13. 13. SFM The Spray forming process  Melt is poured in an inert atmosphere and atomized in a high-speed gas flow (300 m/s) into droplets the size of 10- 200 μm  The droplets undergo rapid solidification ( > 1,000 K/s), which results in an ultrafine grain structure, minimum segregation and an excellent carbide morphology  Melt droplets are targeted to solidify in the form of a billet.  The billet is subsequently forged
  14. 14. Examples of the physical properties of spray formed steels M2 and M35 steels vs. SF steel of identicall composition SFM
  15. 15. Examples of the physical properties of spray formed steels M2 and M35 steels vs. SF steel of identicall composition SFM Tensile strength: +25% Impact strength: +50% ... +100%
  16. 16. SFM Example: D2 cold work steels  D2 steel is a high-chromium tool steel. It is especially favored in application where high wear and abrasion resistance are needed.  Typical applications for D2 Steel inclide stamping, forming, punching, shredding, cutting, toolings
  17. 17. H13 steel cast and annealed As spray formed SFM Hot working steels – example H13  H13 steels are hot working steels with high hardenability and both thermal and wear resistance  Typical applications are pressure die casting tools, extrusion tools, forging dies, hot shear blades, stamping dies, plastic molds. ESR H13 is great for aluminum die-casting tools and plastic mold tools requiring a very high polish.  Spray formed steel of identical composition has a much finer and homogeneous grain structure. Better properties in above-mentioned applications.
  18. 18. . SFM Applications Spray forming is an innovative method for manufacturing high-alloyed steels and other materials Spray formed steels are superior compared to normal cold working, hot working and high speed, and offer an extremely competetive cost to performance ratio. In many applications, such as forging dies....
  19. 19. . SFM Applications Spray forming is an innovative method for manufacturing high-alloyed steels and other materials Spray formed steels are superior compared to normal cold working, hot working and high speed, and offer an extremely competetive cost to performance ratio. In many applications, such as die and toolings for metal extrusion.... Billet to be extruded Die (spray formed steel) Extruded product
  20. 20. . SFM Applications Spray forming is an innovative method for manufacturing high-alloyed steels and other materials Spray formed steels are superior compared to normal cold working, hot working and high speed, and offer an extremely competetive cost to performance ratio. In many applications, such as die and toolings for metal extrusion.... Billet to be extruded Die (spray formed steel) Extruded product
  21. 21. . SFM Applications Spray forming is an innovative method for manufacturing high-alloyed steels and other materials Spray formed steels are superior compared to normal cold working, hot working and high speed, and offer an extremely competetive cost to performance ratio. In many applications, such as die and toolings for HPDC...
  22. 22. . SFM Applications Spray forming is an innovative method for manufacturing high-alloyed steels and other materials Spray formed steels are superior compared to normal cold working, hot working and high speed, and offer an extremely competetive cost to performance ratio. In many applications, such as high-wear parts in construction and mining...
  23. 23. . SFM Applications Spray forming is an innovative method for manufacturing high-alloyed steels and other materials Spray formed steels are superior compared to normal cold working, hot working and high speed, and offer an extremely competetive cost to performance ratio. In many applications, such as cutting, toolmaking, etc....
  24. 24. . SFM Applications ... applications, such as Forging dies Metal extrusion High pressure die casting High-wear parts in construction and mining Cutting; Toolmaking Toolings made of spray formed steel offer typically a double lifetime compared to conventionally produced steels of equal chemical composition
  25. 25. . SFM Applications ... applications, such as Forging dies Metal extrusion High pressure die casting High-wear parts in construction and mining Cutting; Toolmaking Toolings made of spray formed steel offer typically a double lifetime compared to conventionally produced steels of equal chemical composition
  26. 26. SFM Process steps of different steel production methods Powder Metallurgy Electroslag Remelting (ESR) Spray Forming Melting Melting Melting Atomization Casting of electrodes Spraying Classification of powders Preparation of electrodes Forging, rolling Mixing of powders Remelting Heat Treatment Capsulation Diffusion annealing Machining Hot Isostatic Pressing Forging, rolling Forging, rolling Heat Treatment Decapsulation Machining Heat Treatment Machining
  27. 27. SFM Process steps of different steel production methods Powder Metallurgy Electroslag Remelting (ESR) Spray Forming Melting Melting Melting Atomization Casting of electrodes Spraying Classification of powders Preparation of electrodes Forging, rolling Mixing of powders Remelting Heat Treatment Capsulation Diffusion annealing Machining Hot Isostatic Pressing Forging, rolling Forging, rolling Heat Treatment Decapsulation Machining Heat Treatment Machining
  28. 28. SFM Process steps of different steel production methods Powder Metallurgy Electroslag Remelting (ESR) Spray Forming Classification of powders Preparation of electrodes Mixing of powders Remelting Capsulation Diffusion annealing Hot Isostatic Pressing Decapsulation
  29. 29. SFM Process steps of different steel production methods Powder Metallurgy Electroslag Remelting (ESR) Spray Forming Thanks to the short and economical production process, the cost performance ratio of spray formed steels is as good as it is! Classification of powders Preparation of electrodes Mixing of powders Remelting Capsulation Diffusion annealing Hot Isostatic Pressing Decapsulation
  30. 30. Spray formed steel SFM2131 developed by SF Metals has provided its Fortune Global 500 customer in automotive industry with 50% lower toolings costs in forging, compared to high grade ESR hot work steels used by the customer earlier. SFM A case example of SF steels
  31. 31. The chief metallurgist of SF Metals, Dr. Y. YANG, inventor of the Precision Spray Forming (PSF) rapid tooling and manufacturing technology, has been recognized by the Chinese Society of Automotive Engineers with a "First Prize of China Automotive Industry Science and Technology Award 2013". This is for the first commercial trial in the world with PSF concept, which was performed with the spray formed steel grade SFM2131 at Dongfeng Motor Corporation, a Fortune Global 500 company. SFM
  32. 32. The chief metallurgist of SF Metals, Dr. Y. YANG, inventor of the Precision Spray Forming (PSF) rapid tooling and manufacturing technology, has been recognized by the Chinese Society of Automotive Engineers with a "First Prize of China Automotive Industry Science and Technology Award 2013". This is for the first commercial trial in the world with PSF concept, which was performed with the spray formed steel grade SFM2131 at Dongfeng Motor Corporation, a Fortune Global 500 company. SFM
  33. 33. SFM SF Metals  SF Metals employs about 10 highly-skilled people engaged in running the plant, R&D, engineering and sales  SF Metals has a network of about 30 selected manufacturing partners ranging from steel making to machine building, tooling, heat treatment, machining and metal processing techniques such as forging, rolling and extrusion, which enables SFM to flexibly use best available technologies for each customer order and product.  SFM is located in Foshan, the most developed area in China with strong industrial infrastructures. It is just in the neighborhood of Hong Kong, a convenient international logistics hub.  In addition to operation in China, SF Metals has customer service and technical support in Finland ”Price is what you pay. Value is what you get” – Warren Buffet (and we agree!)

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