Permanent Mould Thin Slab Casting and Heat Tretment of 8% Chromium Cold Work Tool Steel (AISI DC 53)

In this study, an alternative method to conventional production methods involving thin section copper permanent mould casting (rapid solidification), hot rolling and heat treatment processes to manufacture AISI DC 53 cold work tool steel, has been investigated. In this new method, solidification of the AISI DC 53 was done in the thin section copper mould instead of traditional ingot casting. After solidification, thin slabs obtained was homogenized to 1150 oC and hold at this temperature for one hour and then hot rolling was be applied. During hot rolling process, about % 30 reduction in thickness of slab was obtained. After hot rolling, heat treatment (austenitizing, quenching and tempering) have been applied to thin slab. The samples have been taken as cast, as rolled and as heat treated (austenitized and tempered) and the microstructural analysis, hardness tests, retained austenite quantity measurement by XRD method have been performed. The heat treatment and tests have been performed for a commercially available AISI DC 53 which is manufactured by thick section ingot casting and rolling. Hardness values of the AISI DC 53 steels produced by traditional route is in the range of 52-54 HRC after austenitization at 1025 oC for one hour and quenched in compressed air and tempered twice at 525 oC for 120 mins. On contrary the permanent mould cast AISI DC 53 after homogenization at 1150 oC and immediately hot rolling then air cooling and austenitized at 1025 oC for one hour then quenched by compressed air and tempered twice at 525 oC for 120 mins have hardness valeus in the range of 55-57 HRC. Experiments have revealed that the properties of new rapid solidified steel in permanent copper mould are better than the commercially available steel and have a more refined microstructure than commercially produces alternative. Therefore, the new proposed method can be used as an alternative manufacturing method for cold-work tool steels.