Hot-isostatically-compacted martensitic mold and die block article and method of manufacture

Claim 1

A martensitic hot work tool steel mold and die block article adapted for use in the manufacture of molds for plastic injection molding, die casting die components, and other hot work tooling components, said article having a hardness within the range of 35 to 50 HRC, a minimum Charpy V-notch impact toughness of 3 foot-pounds when heat treated to a hardness of 44 to 46 HRC and when tested at both 72° F. and 600° F., said article comprising an as hot-isostatically-compacted, fully dense, heat-treated mass of prealloyed particles which contains sulfur within the range of 0.05 to 0.30 weight percent.

Claim 12

A method for manufacturing a martensitic hot work tool steel die block article adapted for use in the manufacture of die casting die components and other hot work tooling components, the article having a hardness within the range of 35 to 50 HRC, and a minimum transverse Charpy V-notch impact toughness of 3 foot pounds when heat treated to a hardness of 44 to 46 HRC and when tested at both 72° F. and 600° F., with the article comprising an as hot-isostatically-compacted, heat treated and fully dense consolidated mass of prealloyed particles, consisting essentially of, in weight percent, 0.32 to 0.45 carbon, 0.20 to 2.00 manganese, 0.05 to 0.30 sulfur, up to 0.03 phosphorous, 0.80 to 1.20 silicon, 4.75 to 5.70 chromium, 1.10 to 1.75 molybdenum, 0.80 to 1.20 vanadium, balance iron and incidental impurities; said method comprising producing said prealloyed particles by gas atomization, hot isostatically compacting the prealloyed particles to full density to form a compact and absent thermomechanical treatment of said compact, annealing said compact, hardening said compact by heating and cooling to produce a martensitic structure, and tempering said compact, which tempering includes at least a double tempering treatment with intermediate cooling to ambient temperature.

Claim 13

A method for manufacturing a martensitic hot work tool steel die block article adapted for use in the manufacture of die casting die components and other hot work tooling components, the article having a hardness within the range of 35 to 50 HRC, and a minimum transverse Charpy V-notch impact toughness of 3 foot pounds when heat treated to a hardness of 44 to 46 HRC and when tested at both 72° F. and 600° F., with the article comprising an as hot-isostatically-compacted, heat treated and fully dense consolidated mass of prealloyed particles, consisting essentially of, in weight percent, 0.32 to 0.45 carbon, 0.20 to 2.00 manganese, 0.05 to 0.30 sulfur, up to 0.03 phosphorous, 0.80 to 1.20 silicon, 4.75 to 5.70 chromium, 1.10 to 1.75 molybdenum, 0.80 to 1.20 vanadium, balance iron and incidental impurities; said method comprising producing said prealloyed particles by gas atomization, hot isostatically compacting the prealloyed particles to full density to form a compact and absent thermomechanical treatment of said compact, annealing said compact, hardening said compact by heating and cooling to produce a martensitic structure, and tempering said compact, which tempering includes at least a double tempering treatment with intermediate cooling to ambient temperature.

Claim 14

A method for manufacturing a martensitic hot work steel die block article adapted for use in the manufacture of die casting die components and other hot work tooling components, the article having a hardness within the range of 35 to 50 HRC and a minimum transverse Charpy V-notch impact toughness of 3 foot pounds when heat treated to a hardness of 44 to 46 HRC and when tested both at 72° F. and 600° F., with the article comprising an as hot-isostatically-compacted, heat treated and fully dense consolidated mass of prealloyed particles, comprising a chemical composition of wrought AISI hot work tool steel to which sulfur has been added within the range of 0.05 to 0.30 weight percent; said method comprising producing said prealloyed particles by gas atomization, hot isostatically compacting the prealloyed particles to full density to form a compact and absent thermomechanical treatment of said compact, annealing said compact, hardening said compact by heating and cooling to produce a martensitic structure, and tempering said compact, which tempering includes at least a double tempering treatment with intermediate cooling to ambient temperature.

Claim 15

A method for manufacturing a martensitic hot work steel die block article adapted for use in the manufacture of die casting die components and other hot work tooling components, the article having a hardness within the range of 35 to 50 HRC and a minimum transverse Charpy V-notch impact toughness of 3 foot pounds when heat treated to a hardness of 44 to 46 HRC and when tested both at 72° F. and 600° F., with the article comprising an as hot-isostatically-compacted, heat treated and fully dense consolidated mass of prealloyed particles, comprising a chemical composition of wrought AISI hot work tool steel to which sulfur has been added within the range of 0.05 to 0.30 weight percent; said method comprising producing said prealloyed particles by gas atomization, hot isostatically compacting the prealloyed particles to full density to form a compact and absent thermomechanical treatment of said compact, annealing said compact, hardening said compact by heating and cooling to produce a martensitic structure, and tempering said compact, which tempering includes at least a double tempering treatment with intermediate cooling to ambient temperature.

Claim 16

A method for manufacturing a martensitic die steel article adapted for use in the manufacture of die casting die components and other hot work tool tooling components, the article having a hardness within the range of 35 to 55 HRC and a minimum transverse Charpy V-notch impact toughness of 3 foot pounds when heat treated to a hardness of 44 to 46 HRC and when tested at both 72° F. and 600° F., the article comprises an as hot-isostatically-compacted, heat treated and fully dense consolidated mass of prealloyed particles comprising a chemical composition of a maraging or precipitation-hardening steel suitable for use as die casting die components and other hot work tooling components and to which sulfur has been added within the range of 0.05 to 0.30 weight percent; said method comprising producing said prealloyed particles by gas atomization, hot isostatically compacting the prealloyed particles to full density to form a compact, and absent thermomechanical treatment of said compact, solution annealing said article to produce a martensitic structure, and age hardening said article to working hardness by heat treating and cooling.

Claim 17

A method for manufacturing a martensitic die steel article adapted for use in the manufacture of die casting die components and other hot work tool tooling components, the article having a hardness within the range of 35 to 55 HRC and a minimum transverse Charpy V-notch impact toughness of 3 foot pounds when heat treated to a hardness of 44 to 46 HRC and when tested at both 72° F. and 600° F., the article comprises an as hot-isostatically-compacted, heat treated and fully dense consolidated mass of prealloyed particles comprising a chemical composition of a maraging or precipitation-hardening steel suitable for use as die casting die components and other hot work tooling components and to which sulfur has been added within the range of 0.05 to 0.30 weight percent; said method comprising producing said prealloyed particles by gas atomization, hot isostatically compacting the prealloyed particles to full density to form a compact, and absent thermomechanical treatment of said compact, solution annealing said article to produce a martensitic structure, and age hardening said article to working hardness by heat treating and cooling.

Claim 18

The method of claims 8, 9 or 10 in which the article contains sulfide particles having a maximum size of 25 microns in the longest direction thereof.

Claim 19

The method of claims 8, 9, or 10 in which the sulfur content is within the range of 0.05 to 0.20% and the minimum Charpy V-notch impact toughness is 5 foot pounds.

Claim 20

The method of claims 8 or 9 wherein the hot isostatic compaction is conducted for up to 12 hours within a temperature range of 1800° F. to 2400° F., and at a pressure in excess of 10,000 psi and said hardening is conducted by heating to a temperature between 1800° F. and 1950° F. for about 1/2 hour per inch of thickness of said article, and quenching to about 150° F. at a minimum rate of 20° F. per minute to produce a martensitic structure and upon reaching a temperature of 150° F. double tempering within a temperature range of 1000° F. to 1200° F. for about 1 hour per inch of thickness and for a minimum of 2 hours plus 2 hours, with cooling to ambient temperature between tempers.