Vanadis 10 structural steel is a premium powder metallurgy (PM) alloy steel celebrated for its exceptional Resistenz tragen, Zähigkeit, Und rote Härte—Ans abgebaut von seiner einzigartigen Chemische Zusammensetzung (Hochchrom, Vanadium, and tungsten content) and advanced manufacturing processes. Unlike conventional tool steels, Vanadis 10 zeichnet sich in hoher Trau aus, Hochstress-Anwendungen, making it a top choice for toolmaking, Bearbeitung, die making, Luft- und Raumfahrt, and automotive industries where durability and precision are non-negotiable. In diesem Leitfaden, Wir werden die wichtigsten Eigenschaften aufschlüsseln, reale Verwendungen, Produktionstechniken, und wie es im Vergleich zu anderen Materialien ist, helping you select it for projects that demand long-lasting performance.
1. Key Material Properties of Vanadis 10 Baustahl
Vanadis 10’s performance stems from its powder metallurgy origins and alloy-rich composition, which deliver a rare balance of wear resistance and toughness—critical for extreme-duty applications.
Chemische Zusammensetzung
Vanadis 10’s formula prioritizes wear resistance and high-temperature stability, mit typischen Bereichen für Schlüsselelemente:
- Kohlenstoff: 1.50-1.60% (high content forms hard carbides with vanadium/tungsten, steigern Resistenz tragen)
- Chrom: 8.00-9.00% (verbessert Korrosionsbeständigkeit und Härtbarkeit, ensuring uniform strength across thick components)
- Vanadium: 4.00-4.50% (core alloying element—forms ultra-hard vanadium carbides, improving wear resistance and Ermüdungsbeständigkeit)
- Molybdän: 1.20-1.50% (boosts high-temperature strength and rote Härte, critical for hot-work dies)
- Wolfram: 1.80-2.20% (aids carbide formation, enhancing wear resistance and thermal stability)
- Mangan: ≤ 0,50% (modest addition improves hardenability without compromising toughness)
- Silizium: ≤0.80% (AIDS-Desoxidation während der Stahlherstellung und stabilisiert die mechanischen Eigenschaften der Hochtemperaturen)
- Schwefel: ≤ 0,030% (Ultra-niedrig zu pflegen Zähigkeit and avoid cracking during heat treatment)
- Phosphor: ≤ 0,030% (streng kontrolliert, um kalte Brechtigkeit zu verhindern, essential for low-temperature applications)
Physische Eigenschaften
| Eigentum | Typical Value for Vanadis 10 Baustahl |
| Dichte | ~ 7,85 g/cm³ (consistent with standard alloy steels, no extra weight penalty for tool designs) |
| Schmelzpunkt | ~ 1450-1500 ° C. (suitable for hot working and heat treatment processes) |
| Wärmeleitfähigkeit | ~ 38 w/(m · k) (at 20°C—sufficient for heat dissipation in high-speed cutting tools) |
| Spezifische Wärmekapazität | ~0.46 kJ/(kg · k) (bei 20 ° C.) |
| Wärmeleitkoeffizient | ~11.0 x 10⁻⁶/°C (20-500°C—lower than high-speed steel, reducing thermal stress in hot-work dies) |
Mechanische Eigenschaften
Nach Standard -Wärmebehandlung (Löschen und Temperieren), Vanadis 10 delivers industry-leading performance for high-wear applications:
- Zugfestigkeit: ~ 2200-2400 MPa (ideal for heavy-duty tools like cold-work dies or high-speed cutting tools)
- Ertragsfestigkeit: ~ 2000-2200 MPA (ensures parts resist permanent deformation under extreme loads, such as extrusion dies or aircraft engine components)
- Verlängerung: ~8-12% (In 50 mm—sufficient ductility for forming complex tool shapes without cracking)
- Härte (Rockwell c): 60-64 HRC (Nach Wärmebehandlung; einstellbar an 55-58 HRC for parts needing extra toughness)
- Schlagfestigkeit (Charpy V-Neoth, 20° C): ~ 30-45 d/cm² (excellent for wear-resistant steels, preventing brittle failure in high-impact tools like stamping dies)
- Ermüdungsbeständigkeit: ~900-1000 MPa (at 10⁷ cycles—critical for dynamic-load tools like high-speed milling cutters or automotive engine parts)
- Resistenz tragen: Exzellent (vanadium and tungsten carbides resist abrasion 5-8x better than conventional tool steels, Werkzeuglebensdauer verlängern)
- Rote Härte: Sehr gut (retains ~58 HRC at 600°C—suitable for high-temperature applications like hot-work dies or aerospace engine components)
Andere Eigenschaften
- Korrosionsbeständigkeit: Gut (chromium addition forms a passive oxide layer—2-3x more resistant to atmospheric corrosion than high-speed steel; suitable for indoor tools or lightly exposed components)
- Verarbeitbarkeit: Gerecht (getemperter Staat, Hb 280-320, requires carbide tools or cubic boron nitride (CBN) tools for efficient cutting; post-heat-treatment grinding is needed for precision edges)
- Zähigkeit: Exzellent (powder metallurgy process eliminates carbide segregation, ensuring uniform toughness across the material—critical for tools subjected to impact)
- Formbarkeit: Mäßig (hot forming recommended for complex shapes—heated to 1050-1100°C for forging into tool blanks; cold forming is limited due to high hardness in annealed state)
2. Real-World Applications of Vanadis 10 Baustahl
Vanadis 10’s unique combination of wear resistance and toughness makes it indispensable in industries where standard materials fail to meet extreme demands. Hier sind seine häufigsten Verwendungszwecke:
Toolmaking
- Schneidwerkzeuge: High-speed cutting tools for machining hard materials (Z.B., Edelstahl, Titanlegierungen) use Vanadis 10—Resistenz tragen Griffe 1000+ Teile pro Werkzeug (vs. 300+ for conventional HSS), reducing tool replacement costs.
- Übungen: Precision drills for aerospace components (Z.B., Turbinenklingen) use Vanadis 10—Härte (60-64 HRC) Schärfe beibehält, Und Zähigkeit avoids breakage in deep-hole drilling.
- Ende Mills: High-performance end mills for milling cast iron or hardened steel use Vanadis 10—rote Härte behält die Festigkeit bei 600 ° C, enabling faster cutting speeds (400+ m/my) and improving production efficiency.
- Reibahlen: Präzisionsreamer für enge Toleranzlöcher (± 0,0005 mm) in medical implants use Vanadis 10—Resistenz tragen maintains hole accuracy over 20,000+ Reichen, reducing quality control rejects.
- Ränen: Internal broaches for shaping gear teeth or keyways use Vanadis 10—uniform toughness ensures consistent tooth quality, and wear resistance extends broach life by 4x vs. standard tool steel.
Fallbeispiel: A tool shop used M2 high-speed steel for end mills machining hardened steel (50 HRC) but faced tool dulling after 250 Teile. Switching to Vanadis 10 extended tool life to 800 Teile (220% länger)—Regieren Sie die Zeit nach der Zeit von 65% und sparen $60,000 jährlich in Arbeits- und Werkzeugkosten.
Bearbeitung
- Drehwerkzeuge: Turning tools for aerospace components (Z.B., Flugzeugfahrwerk) use Vanadis 10—Zugfestigkeit (2200-2400 MPA) withstands high cutting forces, Und Ermüdungsbeständigkeit sichert 15,000+ turns per tool.
- Fräser: Heavy-duty milling cutters for industrial gear manufacturing use Vanadis 10—Resistenz tragen reduces tooth wear by 70% vs. conventional steel, extending cutter life to 500+ Getriebe.
- Shaper tools: Shaper tools for machining large metal plates (Z.B., Schiffsrumpf) use Vanadis 10—Zähigkeit resists impact from uneven surfaces, Und rote Härte handles prolonged cutting without softening.
- Planer tools: Planer tools for flattening large machine bases use Vanadis 10—Resistenz tragen maintains surface finish consistency, reducing post-machining grinding time by 50%.
Die Making
- Cold work dies: Cold-heading dies for fastener manufacturing (Z.B., Bolzen, Schrauben) use Vanadis 10—Resistenz tragen Griffe 500,000+ Stempel (vs. 150,000+ for D2 tool steel), reducing die replacement frequency.
- Heiße Arbeit stirbt: Hot-extrusion dies for aluminum or brass use Vanadis 10—rote Härte behält die Festigkeit bei 600 ° C, Aktivieren 10,000+ extrusion cycles before maintenance.
- Stempeln stirbt: Stamping dies for thick steel sheets (Z.B., 10-15 mm automotive body panels) use Vanadis 10—Zähigkeit resists die cracking from high stamping forces, Und Resistenz tragen extends die life by 3x.
- Extrusion dies: Extrusion dies for plastic or metal profiles (Z.B., Fensterrahmen, aircraft structural parts) use Vanadis 10—Präzision ensures consistent profile dimensions, and wear resistance reduces die reworking costs.
Luft- und Raumfahrt
- Flugzeugkomponenten: High-wear aircraft components (Z.B., landing gear bushings, turbine blade retainers) use Vanadis 10—Resistenz tragen standhalten 10,000+ Flugzyklen, Reduzierung der Ausfallzeiten der Wartung.
- Motorteile: Hochtemperaturteile (Z.B., fuel injector nozzles, compressor blades) use Vanadis 10—rote Härte behält die Festigkeit bei 600 ° C, ensuring reliable performance in jet engines.
- High-performance tools: Aerospace tooling for machining titanium or composite components uses Vanadis 10—Zähigkeit avoids tool breakage in expensive materials, and wear resistance reduces tool costs.
Automobil
- Motorkomponenten: High-performance car engine parts (Z.B., Nockenwellen, Ventillifter) use Vanadis 10—Resistenz tragen reduces component degradation, extending engine life to 300,000+ km.
- Hochfeste Teile: Heavy-duty truck transmission gears or axle components use Vanadis 10—Zugfestigkeit Griffe 1500+ N · m Drehmoment, Und Ermüdungsbeständigkeit verhindert, dass das Versagen wiederholt Spannung.
- Tooling for manufacturing: Automotive stamping dies for body panels or chassis components use Vanadis 10—Haltbarkeit Griffe 1 million+ stampings per die, reducing production downtime for die changes.
3. Manufacturing Techniques for Vanadis 10 Baustahl
Producing Vanadis 10 requires advanced powder metallurgy processes to control carbide distribution and ensure uniform properties—critical for its performance. Hier ist der detaillierte Prozess:
1. Primärproduktion
- Pulvermetallurgie: High-purity iron, Chrom, Vanadium, and other alloy powders are mixed in precise ratios (matching Vanadis 10’s chemical composition). The mixture is compacted into green compacts under high pressure (800-1000 MPA) to form dense blanks.
- Vacuum sintering: Compacts are sintered in a vacuum furnace at 1200-1250°C for 2-4 Std.. This fuses the powder particles into a solid material, eliminating porosity and ensuring uniform carbide distribution—key to Vanadis 10’s toughness.
- Elektrischer Lichtbogenofen (EAF): For small batches—scrap steel and alloying elements are melted at 1650-1750°C. Real-time sensors monitor composition to meet Vanadis 10’s standards, though powder metallurgy is preferred for premium properties.
- Vakuumboden Remelting (UNSER): Optional, for ultra-pure Vanadis 10—sintered ingots are remelted in a vacuum to remove impurities (Z.B., Sauerstoff, Stickstoff), further improving material uniformity and toughness.
2. Sekundärverarbeitung
- Rollen: Sintered ingots are heated to 1050-1100°C and rolled into plates, Barren, or tool blanks via hot rolling mills. Hot rolling refines grain structure and shapes Vanadis 10 into standard tool forms (Z.B., cutter bars, die Lücken).
- Schmieden: Erhitzter Stahl (1000-1050° C) wird in komplexe Formen gedrückt (Z.B., die cavities, cutter heads) using hydraulic presses—improves material density and aligns carbide structure, Verschleißfestigkeit verbessern.
- Wärmebehandlung:
- Glühen: Erhitzt auf 850-900 ° C für 3-5 Std., slow-cooled to 600°C. Reduziert die Härte gegenüber HB 280-320, making Vanadis 10 machinable and relieving internal stress from rolling/forging.
- Löschen und Temperieren: Heated to 1020-1060°C (in Öl gelöscht) then tempered at 500-550°C for 2-3 Std.. Erhöht die Härte zu 60-64 HRC and tensile strength to 2400 MPa—used for high-wear tools like cutting dies.
3. Oberflächenbehandlung
- Beschichtung: Physische Dampfabscheidung (PVD) Beschichtungen (Z.B., Titanaluminiumnitrid, Tialn) are applied to cutting tools—reduces friction, boosts wear resistance by 2-3x, and extends tool life in high-speed machining.
- Nitriding: Nitemperaturnitriding (500-550° C) bildet eine harte Nitridschicht (5-10 μm) on tool surfaces—ideal for dies or cutting tools, enhancing wear resistance without compromising core toughness.
- Kohlensäure: Used for parts needing hard surfaces and tough cores (Z.B., stamping die edges)—heated in a carbon-rich atmosphere (900-950° C) Oberflächen Kohlenstoff hinzufügen, then quenched for extra hardness.
- Polieren: Precision polishing creates a smooth surface (Ra 0.1-0.4 μm) for tools like reamers or dies—reduces material adhesion during cutting/forming, improving part quality and tool life.
4. Qualitätskontrolle
- Inspektion: Visualinspektionsprüfungen für Oberflächenfehler (Z.B., Risse, Porosität) in sintered or forged Vanadis 10—critical for tool safety and performance.
- Testen:
- Zugprüfung: Die Proben werden zum Versagen gezogen, um die Zugsprüfung zu überprüfen (2200-2400 MPA) und Rendite (2000-2200 MPA) strength—ensures compliance with industry standards (Z.B., ISO 4957).
- Tragen Sie Tests: Pin-on-disk tests measure wear rate—Vanadis 10 should show 5-8x lower wear than conventional tool steels.
- Nicht-zerstörerische Tests: Ultraschalltests erkennen interne Defekte (Z.B., voids in sintered material) in large components like dies—avoids tool failure during use.
- Zertifizierung: Each batch of Vanadis 10 receives a material certificate, Überprüfung der chemischen Zusammensetzung und der mechanischen Eigenschaften - Mandatory für die Luft- und Raumfahrt (AS9100) and automotive (IATF 16949) Anwendungen.
4. Fallstudie: Vanadis 10 Structural Steel in Cold-Heading Dies for Fasteners
A fastener manufacturer used D2 tool steel for cold-heading dies (stamping M10 bolts) aber mit zwei Problemen konfrontiert: die wear after 150,000 stampings and high reworking costs. Switching to Vanadis 10 delivered transformative results:
- Die Life Extension: Vanadis 10’s Resistenz tragen extended die life to 550,000 Stempel (267% länger)—cutting die replacement frequency by 70% und sparen $45,000 annually in die costs.
- Quality Improvement: Vanadis 10’s uniform carbide distribution reduced bolt surface defects (Z.B., Burrs) von 90%, lowering quality control rejects and saving $12,000 annually in rework.
- Kosteneffizienz: Despite Vanadis 10’s 60% höhere Materialkosten, Der Hersteller spart $108,000 annually via longer die life and better quality—achieving ROI in 2.8 Jahre.
