Vanadis 10 structural steel is a premium powder metallurgy (PM) alloy steel celebrated for its exceptional se résistance à l'usure, dureté, et dureté rouge—Traits motivés par son unique composition chimique (chrome élevé, vanadium, and tungsten content) and advanced manufacturing processes. Unlike conventional tool steels, Vanadis 10 excelle dans les hauts usages, applications à stress élevé, making it a top choice for toolmaking, usinage, die making, aérospatial, and automotive industries where durability and precision are non-negotiable. Dans ce guide, Nous allons briser ses propriétés clés, Utilise du monde réel, techniques de production, Et comment il se compare à d'autres matériaux, helping you select it for projects that demand long-lasting performance.
1. Key Material Properties of Vanadis 10 Acier de structure
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.
Composition chimique
Vanadis 10’s formula prioritizes wear resistance and high-temperature stability, avec des gammes typiques pour les éléments clés:
- Carbone: 1.50-1.60% (high content forms hard carbides with vanadium/tungsten, renforcement se résistance à l'usure)
- Chrome: 8.00-9.00% (renforcer résistance à la corrosion et durabilité, Assurer une résistance uniforme à travers les composants épais)
- Vanadium: 4.00-4.50% (core alloying element—forms ultra-hard vanadium carbides, improving wear resistance and résistance à la fatigue)
- Molybdène: 1.20-1.50% (boosts high-temperature strength and dureté rouge, critical for hot-work dies)
- Tungstène: 1.80-2.20% (aids carbide formation, enhancing wear resistance and thermal stability)
- Manganèse: ≤0,50% (modest addition improves hardenability without compromising toughness)
- Silicium: ≤0.80% (Aide la désoxydation pendant l'acier et stabilise les propriétés mécaniques à haute température)
- Soufre: ≤0,030% (ultra-faible à maintenir dureté and avoid cracking during heat treatment)
- Phosphore: ≤0,030% (strictement contrôlé pour empêcher la fragilité froide, essential for low-temperature applications)
Propriétés physiques
| Propriété | Typical Value for Vanadis 10 Acier de structure |
| Densité | ~ 7,85 g / cm³ (consistent with standard alloy steels, no extra weight penalty for tool designs) |
| Point de fusion | ~ 1450-1500 ° C (suitable for hot working and heat treatment processes) |
| Conductivité thermique | ~ 38 W /(m · k) (at 20°C—sufficient for heat dissipation in high-speed cutting tools) |
| Capacité thermique spécifique | ~0.46 kJ/(kg · k) (à 20 ° C) |
| Coefficient de dilatation thermique | ~11.0 x 10⁻⁶/°C (20-500°C—lower than high-speed steel, reducing thermal stress in hot-work dies) |
Propriétés mécaniques
Après un traitement thermique standard (trempage et tempérament), Vanadis 10 delivers industry-leading performance for high-wear applications:
- Résistance à la traction: ~ 2200-2400 MPA (ideal for heavy-duty tools like cold-work dies or high-speed cutting tools)
- Limite d'élasticité: ~ 2000-2200 MPA (ensures parts resist permanent deformation under extreme loads, such as extrusion dies or aircraft engine components)
- Élongation: ~8-12% (dans 50 mm—sufficient ductility for forming complex tool shapes without cracking)
- Dureté (Rockwell C): 60-64 HRC (Après un traitement thermique; réglable à 55-58 HRC for parts needing extra toughness)
- Résistance à l'impact (Charpy en V en V, 20° C): ~30-45 J/cm² (excellent for wear-resistant steels, preventing brittle failure in high-impact tools like stamping dies)
- Résistance à la fatigue: ~900-1000 MPa (at 10⁷ cycles—critical for dynamic-load tools like high-speed milling cutters or automotive engine parts)
- Se résistance à l'usure: Excellent (vanadium and tungsten carbides resist abrasion 5-8x better than conventional tool steels, Extension de la durée de vie de l'outil)
- Dureté rouge: Très bien (retains ~58 HRC at 600°C—suitable for high-temperature applications like hot-work dies or aerospace engine components)
Autres propriétés
- Résistance à la corrosion: Bien (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)
- Machinabilité: Équitable (État recuit, HB 280-320, requires carbide tools or cubic boron nitride (Cbn) tools for efficient cutting; post-heat-treatment grinding is needed for precision edges)
- Dureté: Excellent (powder metallurgy process eliminates carbide segregation, ensuring uniform toughness across the material—critical for tools subjected to impact)
- Formabilité: Modéré (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 Acier de structure
Vanadis 10’s unique combination of wear resistance and toughness makes it indispensable in industries where standard materials fail to meet extreme demands. Voici ses utilisations les plus courantes:
Toolmaking
- Outils de coupe: High-speed cutting tools for machining hard materials (Par exemple, acier inoxydable, alliages en titane) use Vanadis 10—se résistance à l'usure poignées 1000+ pièces par outil (contre. 300+ for conventional HSS), reducing tool replacement costs.
- Forets: Precision drills for aerospace components (Par exemple, lames de turbine) use Vanadis 10—dureté (60-64 HRC) maintient la netteté, et dureté avoids breakage in deep-hole drilling.
- Moulin à bout: High-performance end mills for milling cast iron or hardened steel use Vanadis 10—dureté rouge conserve la force à 600 ° C, enabling faster cutting speeds (400+ m / mon) and improving production efficiency.
- Alésus: RAMES DE PRÉCISION pour les trous de tolérance serrée (± 0,0005 mm) in medical implants use Vanadis 10—se résistance à l'usure maintains hole accuracy over 20,000+ rafales, reducing quality control rejects.
- Broches: 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.
Exemple de cas: A tool shop used M2 high-speed steel for end mills machining hardened steel (50 HRC) but faced tool dulling after 250 parties. Switching to Vanadis 10 extended tool life to 800 parties (220% plus long)- Réduire le temps de regring par 65% et sauvegarder $60,000 annuellement dans les coûts de main-d'œuvre et d'outils.
Usinage
- Outils de tour: Turning tools for aerospace components (Par exemple, virent d'atterrissage des avions) use Vanadis 10—résistance à la traction (2200-2400 MPA) withstands high cutting forces, et résistance à la fatigue assure 15,000+ turns per tool.
- Frappeurs: Heavy-duty milling cutters for industrial gear manufacturing use Vanadis 10—se résistance à l'usure reduces tooth wear by 70% contre. conventional steel, extending cutter life to 500+ engrenages.
- Shaper tools: Shaper tools for machining large metal plates (Par exemple, coque) use Vanadis 10—dureté resists impact from uneven surfaces, et dureté rouge handles prolonged cutting without softening.
- Planer tools: Planer tools for flattening large machine bases use Vanadis 10—se résistance à l'usure maintains surface finish consistency, reducing post-machining grinding time by 50%.
Die Making
- Cold work dies: Cold-heading dies for fastener manufacturing (Par exemple, boulons, vis) use Vanadis 10—se résistance à l'usure poignées 500,000+ tirettes (contre. 150,000+ for D2 tool steel), reducing die replacement frequency.
- Le travail chaud meurt: Hot-extrusion dies for aluminum or brass use Vanadis 10—dureté rouge conserve la force à 600 ° C, habilitant 10,000+ extrusion cycles before maintenance.
- Dies à l'estampage: Stamping dies for thick steel sheets (Par exemple, 10-15 mm automotive body panels) use Vanadis 10—dureté resists die cracking from high stamping forces, et se résistance à l'usure extends die life by 3x.
- Extrusion dies: Extrusion dies for plastic or metal profiles (Par exemple, cadres de fenêtre, aircraft structural parts) use Vanadis 10—précision ensures consistent profile dimensions, and wear resistance reduces die reworking costs.
Aérospatial
- Composants d'avion: High-wear aircraft components (Par exemple, landing gear bushings, turbine blade retainers) use Vanadis 10—se résistance à l'usure résister 10,000+ cycles de vol, Réduire les temps d'arrêt de la maintenance.
- Pièces de moteur: Pièces de moteur à haute température (Par exemple, fuel injector nozzles, compressor blades) use Vanadis 10—dureté rouge conserve la force à 600 ° C, ensuring reliable performance in jet engines.
- High-performance tools: Aerospace tooling for machining titanium or composite components uses Vanadis 10—dureté avoids tool breakage in expensive materials, and wear resistance reduces tool costs.
Automobile
- Composants du moteur: High-performance car engine parts (Par exemple, arbres à cames, poussoirs de soupape) use Vanadis 10—se résistance à l'usure reduces component degradation, extending engine life to 300,000+ km.
- Pièces à haute résistance: Heavy-duty truck transmission gears or axle components use Vanadis 10—résistance à la traction poignées 1500+ Couple n · m, et résistance à la fatigue empêche l'échec du stress répété.
- Tooling for manufacturing: Automotive stamping dies for body panels or chassis components use Vanadis 10—durabilité poignées 1 million+ stampings per die, reducing production downtime for die changes.
3. Manufacturing Techniques for Vanadis 10 Acier de structure
Producing Vanadis 10 requires advanced powder metallurgy processes to control carbide distribution and ensure uniform properties—critical for its performance. Voici le processus détaillé:
1. Production primaire
- Métallurgie de la poudre: High-purity iron, chrome, 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 heures. This fuses the powder particles into a solid material, eliminating porosity and ensuring uniform carbide distribution—key to Vanadis 10’s toughness.
- Fournaise à arc électrique (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.
- Arc à l'aspirateur de remontage (NOTRE): Facultatif, for ultra-pure Vanadis 10—sintered ingots are remelted in a vacuum to remove impurities (Par exemple, oxygène, azote), further improving material uniformity and toughness.
2. Traitement secondaire
- Roulement: Sintered ingots are heated to 1050-1100°C and rolled into plates, bars, or tool blanks via hot rolling mills. Hot rolling refines grain structure and shapes Vanadis 10 into standard tool forms (Par exemple, cutter bars, les blancs).
- Forgeage: Acier chauffé (1000-1050° C) est pressé dans des formes complexes (Par exemple, die cavities, cutter heads) using hydraulic presses—improves material density and aligns carbide structure, Amélioration de la résistance à l'usure.
- Traitement thermique:
- Recuit: Chauffé à 850-900 ° C pour 3-5 heures, slow-cooled to 600°C. Réduit la dureté à HB 280-320, making Vanadis 10 machinable and relieving internal stress from rolling/forging.
- Trempage et tempérament: Heated to 1020-1060°C (éteint dans l'huile) then tempered at 500-550°C for 2-3 heures. Augmente la dureté à 60-64 HRC and tensile strength to 2400 MPa—used for high-wear tools like cutting dies.
3. Traitement de surface
- Revêtement: Dépôt de vapeur physique (PVD) revêtements (Par exemple, nitrure d'aluminium en titane, Tialn) are applied to cutting tools—reduces friction, boosts wear resistance by 2-3x, and extends tool life in high-speed machining.
- Nitrative: Nitrade à basse température (500-550° C) Forme une couche de nitrure dur (5-10 μm) on tool surfaces—ideal for dies or cutting tools, enhancing wear resistance without compromising core toughness.
- Carburisant: Used for parts needing hard surfaces and tough cores (Par exemple, stamping die edges)—heated in a carbon-rich atmosphere (900-950° C) Pour ajouter du carbone aux surfaces, then quenched for extra hardness.
- Polissage: Precision polishing creates a smooth surface (Rampe 0.1-0.4 μm) for tools like reamers or dies—reduces material adhesion during cutting/forming, improving part quality and tool life.
4. Contrôle de qualité
- Inspection: L'inspection visuelle vérifie les défauts de surface (Par exemple, fissure, porosité) in sintered or forged Vanadis 10—critical for tool safety and performance.
- Essai:
- Tests de traction: Les échantillons sont prélevés pour ne pas vérifier la traction (2200-2400 MPA) et le rendement (2000-2200 MPA) strength—ensures compliance with industry standards (Par exemple, ISO 4957).
- Tests d'usure: Pin-on-disk tests measure wear rate—Vanadis 10 should show 5-8x lower wear than conventional tool steels.
- Tests non destructeurs: Les tests à ultrasons détecte les défauts internes (Par exemple, voids in sintered material) in large components like dies—avoids tool failure during use.
- Certification: Each batch of Vanadis 10 receives a material certificate, Vérification de la composition chimique et des propriétés mécaniques - Mandatrice pour l'aérospatiale (AS9100) and automotive (IATF 16949) applications.
4. Étude de cas: Vanadis 10 Structural Steel in Cold-Heading Dies for Fasteners
A fastener manufacturer used D2 tool steel for cold-heading dies (stamping M10 bolts) mais a fait face à deux numéros: die wear after 150,000 stampings and high reworking costs. Switching to Vanadis 10 delivered transformative results:
- Die Life Extension: Vanadis 10’s se résistance à l'usure extended die life to 550,000 tirettes (267% plus long)—cutting die replacement frequency by 70% et sauvegarder $45,000 annually in die costs.
- Amélioration de la qualité: Vanadis 10’s uniform carbide distribution reduced bolt surface defects (Par exemple, fouillis) par 90%, lowering quality control rejects and saving $12,000 annually in rework.
- Rentabilité: Despite Vanadis 10’s 60% Coût de matériaux plus élevé, Le fabricant a sauvé $108,000 annually via longer die life and better quality—achieving ROI in 2.8 années.
