Vanadis 10 structural steel is a premium powder metallurgy (Pm) alloy steel celebrated for its exceptional Pakai rintangan, ketangguhan, dan kekerasan merah-TRAITS didorong oleh yang unik Komposisi kimia (kromium tinggi, Vanadium, and tungsten content) and advanced manufacturing processes. Unlike conventional tool steels, Vanadis 10 unggul dengan memakai tinggi, Aplikasi tekanan tinggi, making it a top choice for toolmaking, pemesinan, die making, Aeroangkasa, and automotive industries where durability and precision are non-negotiable. Dalam panduan ini, Kami akan memecah sifat utamanya, Penggunaan dunia nyata, Teknik Pengeluaran, dan bagaimana ia dibandingkan dengan bahan lain, helping you select it for projects that demand long-lasting performance.
1. Key Material Properties of Vanadis 10 Keluli struktur
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.
Komposisi kimia
Vanadis 10’s formula prioritizes wear resistance and high-temperature stability, dengan julat biasa untuk elemen utama:
- Karbon: 1.50-1.60% (high content forms hard carbides with vanadium/tungsten, meningkatkan Pakai rintangan)
- Chromium: 8.00-9.00% (Meningkatkan Rintangan kakisan dan kebolehkerjaan, ensuring uniform strength across thick components)
- Vanadium: 4.00-4.50% (core alloying element—forms ultra-hard vanadium carbides, improving wear resistance and Rintangan Keletihan)
- Molybdenum: 1.20-1.50% (boosts high-temperature strength and kekerasan merah, critical for hot-work dies)
- Tungsten: 1.80-2.20% (aids carbide formation, enhancing wear resistance and thermal stability)
- Mangan: ≤0.50% (modest addition improves hardenability without compromising toughness)
- Silikon: ≤0.80% (aids deoxidation during steelmaking and stabilizes high-temperature mechanical properties)
- Sulfur: ≤0.030% (ultra-rendah untuk mengekalkan ketangguhan and avoid cracking during heat treatment)
- Fosforus: ≤0.030% (dikawal ketat untuk mengelakkan kelembutan sejuk, essential for low-temperature applications)
Sifat fizikal
| Harta | Typical Value for Vanadis 10 Keluli struktur |
| Ketumpatan | ~ 7.85 g/cm³ (consistent with standard alloy steels, no extra weight penalty for tool designs) |
| Titik lebur | ~ 1450-1500 ° C. (suitable for hot working and heat treatment processes) |
| Kekonduksian terma | ~ 38 w/(m · k) (at 20°C—sufficient for heat dissipation in high-speed cutting tools) |
| Kapasiti haba tertentu | ~0.46 kJ/(kg · k) (pada 20 ° C.) |
| Pekali pengembangan haba | ~11.0 x 10⁻⁶/°C (20-500°C—lower than high-speed steel, reducing thermal stress in hot-work dies) |
Sifat mekanikal
Selepas rawatan haba standard (pelindapkejutan dan pembajaan), Vanadis 10 delivers industry-leading performance for high-wear applications:
- Kekuatan tegangan: ~ 2200-2400 MPa (ideal for heavy-duty tools like cold-work dies or high-speed cutting tools)
- Kekuatan hasil: ~ 2000-2200 MPa (ensures parts resist permanent deformation under extreme loads, such as extrusion dies or aircraft engine components)
- Pemanjangan: ~8-12% (dalam 50 mm—sufficient ductility for forming complex tool shapes without cracking)
- Kekerasan (Rockwell c): 60-64 HRC (selepas rawatan haba; boleh laras ke 55-58 HRC for parts needing extra toughness)
- Rintangan kesan (Charpy v-notch, 20° C.): ~ 30-45 d/cm² (excellent for wear-resistant steels, preventing brittle failure in high-impact tools like stamping dies)
- Rintangan Keletihan: ~900-1000 MPa (at 10⁷ cycles—critical for dynamic-load tools like high-speed milling cutters or automotive engine parts)
- Pakai rintangan: Cemerlang (vanadium and tungsten carbides resist abrasion 5-8x better than conventional tool steels, Memperluas hayat alat)
- Kekerasan merah: Sangat bagus (retains ~58 HRC at 600°C—suitable for high-temperature applications like hot-work dies or aerospace engine components)
Sifat lain
- Rintangan kakisan: Baik (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)
- Kebolehkerjaan: Adil (keadaan anil, Hb 280-320, requires carbide tools or cubic boron nitride (Cbn) tools for efficient cutting; post-heat-treatment grinding is needed for precision edges)
- Ketangguhan: Cemerlang (powder metallurgy process eliminates carbide segregation, ensuring uniform toughness across the material—critical for tools subjected to impact)
- Kebolehbaburan: Sederhana (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 Keluli struktur
Vanadis 10’s unique combination of wear resistance and toughness makes it indispensable in industries where standard materials fail to meet extreme demands. Berikut adalah kegunaannya yang paling biasa:
Toolmaking
- Alat pemotongan: High-speed cutting tools for machining hard materials (Mis., Keluli tahan karat, aloi titanium) use Vanadis 10—Pakai rintangan mengendalikan 1000+ Bahagian setiap alat (vs. 300+ for conventional HSS), reducing tool replacement costs.
- Latihan: Precision drills for aerospace components (Mis., bilah turbin) use Vanadis 10—kekerasan (60-64 HRC) mengekalkan ketajaman, dan ketangguhan avoids breakage in deep-hole drilling.
- Kilang akhir: High-performance end mills for milling cast iron or hardened steel use Vanadis 10—kekerasan merah mengekalkan kekuatan pada suhu 600 ° C, enabling faster cutting speeds (400+ m/my) and improving production efficiency.
- Reamers: Reamers ketepatan untuk lubang toleransi ketat (± 0.0005 mm) in medical implants use Vanadis 10—Pakai rintangan maintains hole accuracy over 20,000+ reams, reducing quality control rejects.
- Broaches: 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.
Contoh kes: A tool shop used M2 high-speed steel for end mills machining hardened steel (50 HRC) but faced tool dulling after 250 bahagian. Switching to Vanadis 10 extended tool life to 800 bahagian (220% lebih lama)-Mengalamkan masa regrinding oleh 65% dan penjimatan $60,000 setiap tahun dalam kos buruh dan alat.
Pemesinan
- Alat Lathe: Turning tools for aerospace components (Mis., Gear pendaratan pesawat) use Vanadis 10—kekuatan tegangan (2200-2400 MPA) withstands high cutting forces, dan Rintangan Keletihan memastikan 15,000+ turns per tool.
- Pemotong Pengilangan: Heavy-duty milling cutters for industrial gear manufacturing use Vanadis 10—Pakai rintangan reduces tooth wear by 70% vs. conventional steel, extending cutter life to 500+ gear.
- Shaper tools: Shaper tools for machining large metal plates (Mis., kapal kapal) use Vanadis 10—ketangguhan resists impact from uneven surfaces, dan kekerasan merah handles prolonged cutting without softening.
- Planer tools: Planer tools for flattening large machine bases use Vanadis 10—Pakai rintangan maintains surface finish consistency, reducing post-machining grinding time by 50%.
Die Making
- Cold work dies: Cold-heading dies for fastener manufacturing (Mis., bolt, skru) use Vanadis 10—Pakai rintangan mengendalikan 500,000+ setem (vs. 150,000+ for D2 tool steel), reducing die replacement frequency.
- Kerja panas mati: Hot-extrusion dies for aluminum or brass use Vanadis 10—kekerasan merah mengekalkan kekuatan pada suhu 600 ° C, membolehkan 10,000+ extrusion cycles before maintenance.
- Stamping mati: Stamping dies for thick steel sheets (Mis., 10-15 mm automotive body panels) use Vanadis 10—ketangguhan resists die cracking from high stamping forces, dan Pakai rintangan extends die life by 3x.
- Extrusion dies: Extrusion dies for plastic or metal profiles (Mis., bingkai tingkap, aircraft structural parts) use Vanadis 10—ketepatan ensures consistent profile dimensions, and wear resistance reduces die reworking costs.
Aeroangkasa
- Komponen pesawat: High-wear aircraft components (Mis., landing gear bushings, turbine blade retainers) use Vanadis 10—Pakai rintangan bertahan 10,000+ kitaran penerbangan, Mengurangkan downtime penyelenggaraan.
- Bahagian enjin: Bahagian enjin suhu tinggi (Mis., fuel injector nozzles, compressor blades) use Vanadis 10—kekerasan merah mengekalkan kekuatan pada suhu 600 ° C, ensuring reliable performance in jet engines.
- High-performance tools: Aerospace tooling for machining titanium or composite components uses Vanadis 10—ketangguhan avoids tool breakage in expensive materials, and wear resistance reduces tool costs.
Automotif
- Komponen enjin: High-performance car engine parts (Mis., camshafts, Pengangkat injap) use Vanadis 10—Pakai rintangan reduces component degradation, extending engine life to 300,000+ km.
- Bahagian kekuatan tinggi: Heavy-duty truck transmission gears or axle components use Vanadis 10—kekuatan tegangan mengendalikan 1500+ N · m tork, dan Rintangan Keletihan menghalang kegagalan daripada tekanan berulang.
- Tooling for manufacturing: Automotive stamping dies for body panels or chassis components use Vanadis 10—ketahanan mengendalikan 1 million+ stampings per die, reducing production downtime for die changes.
3. Manufacturing Techniques for Vanadis 10 Keluli struktur
Producing Vanadis 10 requires advanced powder metallurgy processes to control carbide distribution and ensure uniform properties—critical for its performance. Inilah proses terperinci:
1. Pengeluaran utama
- Metalurgi serbuk: High-purity iron, Chromium, 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 jam. This fuses the powder particles into a solid material, eliminating porosity and ensuring uniform carbide distribution—key to Vanadis 10’s toughness.
- Relau arka elektrik (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.
- Vacuum arc remelting (Kami): Pilihan, for ultra-pure Vanadis 10—sintered ingots are remelted in a vacuum to remove impurities (Mis., oksigen, nitrogen), further improving material uniformity and toughness.
2. Pemprosesan sekunder
- Bergulir: Sintered ingots are heated to 1050-1100°C and rolled into plates, bar, or tool blanks via hot rolling mills. Hot rolling refines grain structure and shapes Vanadis 10 into standard tool forms (Mis., cutter bars, kosong).
- Menunaikan: Keluli yang dipanaskan (1000-1050° C.) ditekan ke dalam bentuk kompleks (Mis., die cavities, cutter heads) using hydraulic presses—improves material density and aligns carbide structure, Meningkatkan rintangan haus.
- Rawatan haba:
- Penyepuhlindapan: Dipanaskan hingga 850-900 ° C 3-5 jam, slow-cooled to 600°C. Mengurangkan kekerasan ke HB 280-320, making Vanadis 10 machinable and relieving internal stress from rolling/forging.
- Pelindapkejutan dan pembajaan: Heated to 1020-1060°C (dipadamkan dalam minyak) then tempered at 500-550°C for 2-3 jam. Meningkatkan kekerasan kepada 60-64 HRC and tensile strength to 2400 MPa—used for high-wear tools like cutting dies.
3. Rawatan permukaan
- Salutan: Pemendapan wap fizikal (Pvd) salutan (Mis., Titanium aluminium nitride, Tialn) are applied to cutting tools—reduces friction, boosts wear resistance by 2-3x, and extends tool life in high-speed machining.
- Nitriding: Low-temperature nitriding (500-550° C.) forms a hard nitride layer (5-10 μm) on tool surfaces—ideal for dies or cutting tools, enhancing wear resistance without compromising core toughness.
- Karburisasi: Used for parts needing hard surfaces and tough cores (Mis., stamping die edges)—heated in a carbon-rich atmosphere (900-950° C.) Untuk menambah karbon ke permukaan, then quenched for extra hardness.
- Menggilap: 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. Kawalan kualiti
- Pemeriksaan: Pemeriksaan pemeriksaan visual untuk kecacatan permukaan (Mis., retak, keliangan) in sintered or forged Vanadis 10—critical for tool safety and performance.
- Ujian:
- Ujian tegangan: Sampel ditarik ke kegagalan untuk mengesahkan tegangan (2200-2400 MPA) dan hasil (2000-2200 MPA) strength—ensures compliance with industry standards (Mis., ISO 4957).
- Pakai ujian: Pin-on-disk tests measure wear rate—Vanadis 10 should show 5-8x lower wear than conventional tool steels.
- Ujian tidak merosakkan: Ujian ultrasonik mengesan kecacatan dalaman (Mis., voids in sintered material) in large components like dies—avoids tool failure during use.
- Pensijilan: Each batch of Vanadis 10 receives a material certificate, verifying chemical composition and mechanical properties—mandatory for aerospace (AS9100) and automotive (IATF 16949) aplikasi.
4. Kajian kes: Vanadis 10 Structural Steel in Cold-Heading Dies for Fasteners
A fastener manufacturer used D2 tool steel for cold-heading dies (stamping M10 bolts) tetapi menghadapi dua isu: die wear after 150,000 stampings and high reworking costs. Switching to Vanadis 10 delivered transformative results:
- Die Life Extension: Vanadis 10’s Pakai rintangan extended die life to 550,000 setem (267% lebih lama)—cutting die replacement frequency by 70% dan penjimatan $45,000 annually in die costs.
- Quality Improvement: Vanadis 10’s uniform carbide distribution reduced bolt surface defects (Mis., burrs) oleh 90%, lowering quality control rejects and saving $12,000 annually in rework.
- Kecekapan kos: Despite Vanadis 10’s 60% Kos bahan yang lebih tinggi, Pengilang disimpan $108,000 annually via longer die life and better quality—achieving ROI in 2.8 tahun.
