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

1. SFM
Spray formed steels
The next generation high-performance tooling material
Lauri Eklin
SF Metals Ltd.

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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. Examples of the physical properties of spray formed steels
M2 and M35 steels vs. SF steel of identicall composition
SFM

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. 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. 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. .
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. .
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. .
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. .
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. .
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. .
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. .
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. .
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. 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. 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. 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. 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. 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. 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. 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. 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!)