Se stai cercando un servizio conveniente, high-strength alloy steel for mechanical parts like gears or shafts—JIS SCR440 alloy steel is an excellent choice. Come acciaio legato al cromo standard giapponese, equilibra la temprabilità solida, resistenza all'usura, e lavorabilità. Questa guida analizza tutto ciò che devi sapere, dalla sua composizione chimica agli usi nel mondo reale, to help you make informed decisions for your projects.
1. Material Properties of JIS SCR440 Alloy Steel
JIS SCR440’s performance is rooted in its well-balanced properties, all compliant with Japan’sJIS G4105 standard. Let’s explore each key aspect clearly.
1.1 Composizione chimica
The elements in JIS SCR440 work together to boost strength, durezza, e durata. Below is the standard composition range:
| Elemento | Simbolo | Composition Range (%) | Key Role in the Alloy |
|---|---|---|---|
| Carbonio (C) | C | 0.38 – 0.45 | Enhancesresistenza alla trazione and surface hardness; critical for wear-resistant parts |
| Cromo (Cr) | Cr | 0.90 – 1.20 | Miglioratemprabilità Eresistenza alla corrosione; prevents oxidation at moderate temperatures |
| Manganese (Mn) | Mn | 0.60 – 0.90 | Aumentalavorabilità and grain refinement; reduces brittleness after heat treatment |
| Silicio (E) | E | 0.15 – 0.35 | Acts as a deoxidizer during steelmaking; strengthens the alloy without losing ductility |
| Molibdeno (Mo) | Mo | ≤ 0.15 | Trace amounts slightly enhance high-temperature stability; not a primary alloying element |
| Nichel (In) | In | ≤ 0.25 | Minimal content; small amounts slightly improveimpact toughness |
| Zolfo (S) | S | ≤ 0.030 | Kept low to avoid cracking and brittleness in high-stress applications |
| Fosforo (P) | P | ≤ 0.030 | Limited to prevent cold brittleness (fracture in low-temperature environments) |
| Vanadium (V) | V | ≤ 0.03 | Tiny amounts refine grain structure for uniform strength across the part |
1.2 Proprietà fisiche
These traits determine how JIS SCR440 behaves in different working conditions—like temperature changes or magnetic fields:
- Densità: 7.85 g/cm³ (consistent with most ferrous alloys, easy to integrate into existing designs)
- Punto di fusione: 1430 – 1450°C (high enough for applicazioni ad alta temperatura like industrial rollers or engine parts)
- Conduttività termica: 45 Con/(m·K) at 20°C (retains heat well, suitable for parts that operate continuously)
- Specific heat capacity: 470 J/(kg·K) at 20°C (absorbs heat steadily, avoiding warping from sudden temperature swings)
- Thermal expansion coefficient: 12.0 μm/(m·K) (low expansion, critical for precision parts like gears or shafts)
- Magnetic properties: Ferromagnetico (attira i magneti, useful for tools like magnetic clamps or sensors)
1.3 Proprietà meccaniche
JIS SCR440’s full mechanical strength is unlocked aftertempra + tempera (its standard heat treatment). Below are typical values tested to Japanese standards:
| Proprietà | Valore tipico | Test Standard (LUI) |
|---|---|---|
| Resistenza alla trazione | ≥ 1000 MPa | JIS Z2241 |
| Yield strength | ≥ 800 MPa | JIS Z2241 |
| Allungamento | ≥ 12% | JIS Z2241 |
| Reduction of area | ≥ 45% | JIS Z2241 |
| Durezza (Brinell) | 229 – 286 HB | JIS Z2243 |
| Durezza (Rockwell C) | 23 – 30 HRC | JIS Z2245 |
| Durezza (Vickers) | 230 – 290 alta tensione | JIS Z2244 |
| Impact toughness | ≥ 50 J | JIS Z2242 |
| Fatigue strength | ~520 MPa | JIS Z2273 |
1.4 Altre proprietà
- Resistenza alla corrosione: Moderare (resists mild moisture, oli, and industrial chemicals; use zinc plating or paint for outdoor/humid environments)
- Resistenza all'usura: Bene (grazie a cromo (Cr) e trattamento termico; suitable for moving parts like bearings or rollers)
- Lavorabilità: Giusto (softer in annealed state; use high-speed steel (HSS) or carbide tools with cutting fluid to reduce tool wear)
- Weldability: Acceptable (preheat to 250 – 300°C and post-weld heat treat to avoid cracking; use low-hydrogen electrodes)
- Temprabilità: Eccellente (heat treatment penetrates deeply, ensuring uniform strength in thick parts like heavy machinery shafts)
2. Applications of JIS SCR440 Alloy Steel
JIS SCR440’s mix of strength, convenienza, and versatility makes it ideal forapplicazioni ad alto stress in tutti i settori. Ecco i suoi usi più comuni, con esempi del mondo reale:
2.1 Industria automobilistica
Cars and commercial vehicles rely on its durability for key mechanical parts:
- Ingranaggi: A Japanese automaker uses it for manual transmission gears—its resistenza all'usura extends gear life by 30% contro. acciaio al carbonio.
- Alberi: Compact trucks use JIS SCR440 drive shafts; suo yield strength (≥800 MPa) handles 20-ton loads without bending.
- Bolts and fasteners: High-performance sedans use it for engine mount bolts—their resistenza alla trazione (≥1000 MPa) resist vibration loosening.
2.2 Industria meccanica
Industrial machines need parts that last through continuous use:
- Cuscinetti: A manufacturing plant uses it for conveyor belt bearings—its durezza (229–286 HB) cuts maintenance downtime by 20%.
- Rollers: Printing machinery uses it for pressure rollers; suo resistenza alla fatica (~520 MPa) withstands repeated contact with paper.
- Sorgenti: Small construction tools (like jackhammers) use it for compression springs; its elasticity (from tempering) maniglie 8,000+ cicli.
2.3 Macchinari pesanti
For large-scale equipment, it provides reliable strength:
- Crane shafts: Small port cranes use it for hoist shafts—its impact toughness (≥50 J) prevents fracture when lifting 25-ton containers.
- Structural fasteners: Agricultural machinery (like tractors) uses JIS SCR440 bolts; loro resistenza alla corrosione (with anti-rust coating) stands up to mud and rain.
3. Manufacturing Techniques for JIS SCR440 Alloy Steel
To maximize JIS SCR440’s performance, follow these industry-proven manufacturing steps:
3.1 Steelmaking Processes
It’s typically produced using two methods:
- Forno ad arco elettrico (EAF): Most common for medium batches. Scrap steel is melted with electrodes, Poi cromo (Cr) is added to reach the target composition. EAF is flexible and reduces waste, ideal for custom parts like large gears.
- Fornace ad ossigeno basico (BOF): Used for mass production. Molten iron is mixed with oxygen to remove impurities, then alloy elements are added. BOF is faster and cost-effective for standard parts like bolts.
3.2 Trattamento termico
Heat treatment is critical to unlock JIS SCR440’s full potential. The standard process for high-stress parts is:
- Ricottura: Riscaldare a 820 – 850°C, cool slowly. Softens the alloy for easier machining (cuts tool wear by 30%).
- Tempra: Riscaldare a 840 – 860°C, cool rapidly in oil. Hardens the steel to reach resistenza alla trazione ≥1000 MPa.
- Temperamento: Riscaldare a 500 – 550°C, cool in air. Reduces brittleness while retaining strength—critical for parts like gears or shafts.
- Carburazione (optional): Riscaldare a 900 – 950°C in a carbon-rich atmosphere. Adds a hard outer layer (0.8–1.0 mm thick) to boost resistenza all'usura (ideal for bearings).
3.3 Forming Processes
JIS SCR440 is shaped into parts using:
- Forgiatura: Hammered or pressed at 1100 – 1200°C. Aligns the metal’s grain structure, increasing resistenza alla trazione di 12% contro. cast parts. Used for gears, alberi, and crane components.
- Rotolamento: Passed through rollers to make bars, fogli, or rods. Used for basic shapes like bolt blanks or spring stock.
- Estrusione: Pushed through a die to make complex shapes (per esempio., hollow shafts). Ideal for precision parts like automotive transmission components.
3.4 Machining Processes
After forming, parts are finished with precision machining:
- Girando: Uses a lathe to make cylindrical parts (per esempio., alberi). Use cutting fluid (per esempio., mineral oil) to prevent overheating and tool wear.
- Fresatura: Uses a rotating cutter to shape gear teeth or bearing races. Carbide tools work best for high precision (per esempio., gear tooth tolerance ±0.02 mm).
- Perforazione: Creates holes for bolts or fasteners. High-speed drills (900–1400 RPM) avoid cracking.
- Rettifica: Smooths surfaces to tight tolerances (per esempio., ±0.01 mm for bearing inner rings). Migliora resistenza all'usura by reducing surface friction.
4. Caso di studio: JIS SCR440 in Automotive Transmission Gears
A Japanese automotive parts supplier faced a problem: their carbon steel transmission gears failed after 160,000 km, leading to customer complaints. They switched to JIS SCR440—and solved the issue.
4.1 Sfida
The supplier’s gears were used in compact cars with frequent city driving (start-stop cycles). Carbon steel gears had lowresistenza alla fatica (400 MPa) Eresistenza all'usura, leading to tooth wear and transmission slippage. The failure rate was 6% per year, hurting the supplier’s reputation.
4.2 Soluzione
They switched to JIS SCR440 gears, utilizzando:
- Forgiatura (1150°C) to align grain structure and boost strength.
- Tempra (850°C) + tempera (530°C) to reach 820 MPa yield strength E 55 J impact toughness.
- Precision grinding to smooth gear teeth, riducendo l'attrito e l'usura.
4.3 Risultati
- Service life: Gears now last 320,000 km—double the previous lifespan.
- Risparmio sui costi: Reduced replacement part costs by ¥240,000 per year.
- Affidabilità: Failure rate dropped from 6% A 1%, restoring customer trust.
5. Comparative Analysis: JIS SCR440 vs. Other Materials
How does JIS SCR440 stack up against common alternatives? Below is a side-by-side comparison of key traits:
| Materiale | Resistenza alla trazione | Resistenza all'impatto | Resistenza alla corrosione | Costo (contro. JIS SCR440) | Ideale per |
|---|---|---|---|---|---|
| JIS SCR440 | ≥1000 MPa | ≥50 J | Moderare | 100% (base) | High-stress, cost-sensitive parts |
| Acciaio inossidabile (SUS304) | 515 MPa | 60 J | Eccellente | 170% | Food/chemical equipment |
| Acciaio al carbonio (S45C) | 600 MPa | 35 J | Basso | 50% | Parti a bassa sollecitazione (parentesi) |
| Acciaio legato (SCM440) | 1080 MPa | 60 J | Moderare | 110% | Componenti ad alte prestazioni (alberi motore) |
| Alluminio (A6061) | 310 MPa | 110 J | Bene | 120% | Lightweight parts (car frames) |
Key takeaway: JIS SCR440 offers betterresistenza alla trazione than carbon steel and aluminum, while being cheaper than SCM440 or stainless steel. It’s the best value forhigh-stress, cost-sensitive applications like standard transmission gears or medium-duty shafts.
Yigu Technology’s Perspective on JIS SCR440 Alloy Steel
Alla tecnologia Yigu, JIS SCR440 is a go-to for clients needing reliable, affordable high-strength parts. We’ve supplied it for automotive gears and machinery shafts for 10+ anni, and itstemprabilità Eresistenza all'usura consistently meet mid-range performance needs. We often recommend annealing for easier machining and anti-rust coatings for outdoor use, helping clients cut maintenance costs by 25%. For manufacturers balancing performance and budget, JIS SCR440 is an unbeatable choice.
FAQ About JIS SCR440 Alloy Steel
1. Can JIS SCR440 be used in cold temperatures?
Yes—itsimpact toughness (≥50 J) lets it perform reliably at temperatures down to -15°C. For colder climates (-20°C or below), adjust the tempering process (lower to 480–500°C) to boost toughness to ≥60 J.
2. What’s the difference between JIS SCR440 and SCM440?
SCM440 containsmolibdeno (Mo) (0.15–0.25%), giving it 8% più altoresistenza alla trazione and better high-temperature stability than SCR440. Choose SCM440 for extreme stress; SCR440 for cost-sensitive, medium-stress parts.
3. How to improve JIS SCR440’s corrosion resistance?
Add a protective coating: zincatura (for outdoor bolts), verniciatura a polvere (for structural components), or chrome plating (for moving parts like bearings). These treatments extend service life in humid environments by 5–8 years.