Spray-formed high-speed steel is an advanced powder metallurgy (PM) high-speed steel manufactured by the spray forming process — an innovative rapid solidification technology. This novel method of processing avoids macrosegregation of alloying elements and influences a more homogeneous microstructure containing attributes of those seen in conventional powder metallurgy materials.
A combination of rapid solidification and powder metallurgy, spray-formed HSS provides better toughness, wear resistance, and red hardness while providing several benefits such as operating without grinding and offering a consistent, high-quality, moderate-priced product for both tough tool and industrial applications.
First,the raw materials are heated into molten metal,and then gas atomized;
Under the action of the gas jet, the droplets are accelerated to fly and rapidly cooled;
When the high-speed fiying droplets collide in the precipitator,the spherical particles are impacted by the impact. It becomes flat to form a sputtering sheet;
The particles solidify rapidly through the cooling effect of the precipitator,and accumulate and form under the action of self- fluxing.
High-speed steels (HSS) are used in cutting tools for their wear resistance and red hardness. These properties come from a martensitic matrix with carbides of W, Mo, and V.
Traditional HSS has limitations like low toughness due to coarse microstructures. Techniques like powder metallurgy (PM) refine these structures but are costly due to hot isostatic pressing (HIP).
Spray forming is a cost-effective alternative that produces finer microstructures with better toughness and hot workability. It uses N2 gas for atomization and requires hot forging to eliminate porosity. The development of twin atomizers allows the production of larger billets, up to 500 mm in diameter.
This work compares the microstructure and toughness of spray-formed and conventional AISI M3:2 HSS, focusing on hot working temperature effects.
High-Speed Steel (HSS) prepared by spray forming is used for high-performance gear cutting tools because of its favorable red-hardness, wear resistance, and toughness. It is most effective for high-volume, high-precision and high-load machining.
Key tool types include:
Application Industries:
Automotive, Construction Equipment, Aerospace, Defence, Gear Box Manufacturers, Hydraulics Systems.
Core Advantages:
Excellent in red hardness for high-speed, high-heat applications.
Excellent wear resistance for long tool life.
Fine and homogeneous microstructure provides improved cutting edges and longer tool life.
Very good dimensional and tooth shape stability.
Typical Benefits:
Productivity is significantly improved, resulting in a decrease in tool changes, better gear surface finish quality, and longer tool and workpiece life.
Spray forming is a promising manufacturing process that combines the advantages of casting and PM technology. Here is why it’s the top option for producing premium HSS:
The company has a strong technical force, and has successfully developed the domestic original new technology of rapid solidification electroslag remelting and the new technology of high-speed steel round rod three pressing and three drawing. Rare earth element modification method won the national invention patent. Strive for excellent products, strive for China 2025 China made in the vanguard of quality enterprises.
Unique Rapid solidification electroslag remelting(RS ESR）, the ingot has a small, uniform carbide size, and compact structure, the characteristics of grain boundary binding force are stronger, made of the steel ingot material, which has good abrasion resistance, red hardness, and toughness much better than the domestic same type products, carbide grain size and distribution better than imported(Japan and Europe) materials.
The performance is obviously better than similar domestic products, carbide shape, and distribution, as well as many imported materials.
Our raw material advantages: we don’t use scrap recycling, our HSS raw material components :
high alloy elements (W, Cr, Mo, V, Si, Mn, Co) + High purity low alloy steel ( low carbon content, low impurities, high quality cold rolled sheet) which is close to pure iron, So our raw material cost his higher than HSS scrap recycling, and our HSS purity is much better than normal;
RS-ESR:
The special process can make the carbide grain size much smaller, the ledeburite carbide network much smaller, to reduce material segregation. and improve material quality.
The technology has been researched and developed by us, it’s a unique technology in China.
The rapid solidification and fast speed cooling lead to a shallow melting pool, and the carbide will solidify before it is too late to grow.
(fast cooling)→(rapid solidification) (Shorten the growth time of carbide size, so it never grows to a large size )
To increase the forging ratio to improve internal organization.
Make the carbide size smaller and distribution more even, which can make the Carbide distribution achieve grade 4
