DOOSAN PLASTIC MOLD STEELCREATING VALUE FOR THE WORLD

GLOBAL LEADER IN POWER & WATER

Doosan has continued to research and develop technology for producing outstandingmold steel, which is now being supplied for the benefit of customers worldwide. Plastic mold steel from Doosan is also accelerating the development of industry.

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION

CONTENTS

PLASTIC MOLD STEELS

HP1A / HP4A(D1) / HP4MA(D2) 6

HIGH QUALITY PLASTIC MOLD STEELS

HP70 / HEMS1A 10

PHYSICAL PROPERTIES 13

MANUFACTURING PROCESS 14

PLASTIC MOLD STEELS

03

INTRODUCTION

PLASTIC MOLD STEELS

Mirror Polishability >

General Products Semi-TransparentProducts

TransparentProducts

Super mirrorfinish ProductsH

ardn

ess

> HP1AHP4A(D1)

HP4MA(D2)

HP70

HEMS1A

Polishing Property(Schematic Diagram)

Doosan’s Plastic Mold Steel “HP”

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION

HP1A

HP4A(D1)

HP4MA(D2)

HP70

HEMS1A

1050Improved

4140Improved

P20Improved

P21Improved

420Improved

S55CImproved

SCM44OImproved

SNCMImproved

Daido’sNAK80

SUS420J2Improved

1.1210Improved

1.2311Improved

1.2738Improved

-

1.2083Improved

DOOSANBRAND D/N

REFERENCE SPECIFICATION

DIN AISI JIS

-

618Improved

718Improved

-

STAVAXImproved

ASSAB

SUPPLIEDCONDITION

APPLICATIONS

Annealed

Prehardened

Prehardened •General purpose large sizemold base

•Core & Cavity•General purpose mold for

Mass-production

•Higher hardness mold•Bumper mold•General purpose mold for

Mass-production

•High grade mold base formirror surface & EDM requirement

•Corrosion resistant precisionplastic mold

•Glass mold & TV brauntube mold

Prehardened

Prehardened

05

DOOSAN Heavy Industries & Construction Co., Ltd. (DOOSAN) has been producing various types of casting

& forging products for the many years ranging from power generator, chemical vessel, steel mill, ship

building to cement industries.

Since being founded, DOOSAN has also supplied plastic mold steels and tool steels to the high technology

sectors such as electric, electromagnetic, optical, telecommunication industries as well as the fields of

semiconductors, precision machinery, construction machinery, automobile, etc.

DOOSAN is very pleased to be given the chance to supply its products to the world. As mentioned above,

its products are well known for their excellence in quality. Doosan is proud to inform you that it has patents

for plastic mold steels in Korea as well as acquired certificate of ISO 9001 (ANSI / ASQC Q91).

DOOSAN will continuously do its very best in improving the quality of plastic mold steels to its limit. We

will promise satisfaction to all of our customers.

New types of high-quality free-cutting steel for plastic moldings, HP series plastic mold steels, have been

developed under a strict quality assurance system with DOOSAN’s modern facilities.

Compared with the conventional steel materials of other companies, the machining time for our new

products can be reduced by a maximum of 40%. Because of special alloy elements in our HP series plastic

mold steels, one can obtain better etching workability, polishing workability and weldability than in many

other products.

As a result, not only is the efficiency of metal mold work improved and the service life of the cutting tools

greatly extended, but one can also make excellent plastic products. HP steels and HEMS1A are high

performance and high-precision plastic mold steel.

Use of our newly developed HP steels and HEMS1A can make a major contribution to the improvement

productivity and rationalization of production.

DOOSAN’s Plastic Mold Steels

HP1A

•General Purpose for Plastic Molding

•Outstanding Machinability

•Less Residual Stress and Distortion

HP4A(D1)

•Excellent Machinability

•Superior Cleanliness, Weldability and

Photo-etching

•Better Hardness Distribution

HP4MA(D2)

•Better Machinability

•Outstanding Hardness Distribution

and Wear Resistance

•Superior Cleanliness and Photo-

etching

•Adopting new concept in alloy design to make up for weak points with maintaining strong points

•Optimizing quality heat treatments to get mechanical properties.

■ Chemical Compositions

HP1A / HP4A(D1) / HP4MA(D2)

PLASTIC MOLD STEELS

Material Characteristics

MELTING

•Superior Cleanliness due to High

Vacuum Degassing Process

FORGING

•No Solidification Defect by Using

130MN & 42MN Press

HEAT TREATMENT

•Excellent Mechanical Properties by

Optimal Heat Treatment

Manufacturing Characteristics

Main Concepts of Developing HP4A(D1) & HP4MA(D2)

Quality Properties

(Unit :wt%)

Material HP1A HP4A(D1) HP4MA(D2)

C >0.50 0.25 ~ 0.35 0.25 ~ 0.35

Ni <0.50 0.20~0.50 0.20~0.50

Cr - 1.00 ~ 1.50 1.50 ~ 2.00

Mo - 0.20~0.40 0.30~0.60

SpecialAdded Added

Alloy

■ Mechanical Properties

Material HP1A HP4A(D1) HP4MA(D2)

SurfaceHS 28~33 HRc 28~32 HRc 31~34Hardness

YieldStrength 350 ~ 450 650 ~ 800 750 ~ 900(N/mm2)

TensileStrength 700 ~ 800 800 ~ 900 900 ~ 1100(N/mm2)

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION

07

Har

dnes

s(H

Rc) 36

34

32

30

28

26

24

22

20

-200 -100 0 100 200

HP4MA (D2)HP4A (D1)

Distance from center(mm)

Stre

ngth

(N /

㎟)

HP1A HP4A (D1) HP4MA (D2)

700

600

500

400

300

200

1000

900

800

100

■ Cross Sectional Hardness DistributionHardness is uniformly distributed throughoutthe cross sectionYield Tensile

■ Photo etching

There is no serious trouble in the most segregated part of 770mm heavy block.

■ SegregationHP4A (D1) and HP4MA (D2) are superior to HP1Ain segregation.

HP4A(D1) HP4MA(D2)

HP1A HP4MA(D2)

■ Mechanical Properties Graph

HP1ARepair Welding Manual

DescriptionHP4A(D1) HP4MA(D2)

Remarks

AWSER70S-4ER70S-6

AWSER80S-B2ER80S-G

AWSER80S-B2ER80S-G

ER9OS-B3

Welding Rod : 1.6Ø, 2.4Ø

Fuel : LNGFuel Pressure : 0.5 kg/cm2

TP (Holding Temperature)HP1A : 270±20℃HP4A(D1) : 350±20℃HP4MA(D2) : 320±20℃

Required Polishing and Etching Workability

250±50℃(200~300)

WeldingPost Heating

(250~350℃)Preheating

WeldingSlow cooling(≤50℃/hr)

300℃

PWHT

(500~600℃)

(200~350℃)Preheating

Filler Metals

Preheat Temp.

Post Heat Treatment

Post-Weld HeatTreatment (PWHT)

*Slow cooled using insulating materials.

300±50℃(250~350)

250±50℃(200~300)

30(min) / inch

1-2hr

*

*

■ Procedures for Repair Welding

In case of design change and defects during operation, repair welding has to be performed. Due to high strength of mold steel repair welding requires the extreme care and strict supervision.

max.100 OC/hr

TP

VBm

ax (m

m)

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0.021 3 40

1.2311

HP4A(D1)

Cutting Distance (mm) Cutting Distance (mm)

Life of tool

VBm

ax (m

m) 0.7

0.6

0.5

0.4

0.3

0.2

0.1

0.0

21 3 40

1.2738

1.6 3.3 1.5 3.2

HP4MA(D2)

Life of tool

■ Machinability

HP1A / HP4A(D1) / HP4MA(D2)

PLASTIC MOLD STEELS

HP4A(D1) & HP4MA(D2) give 2 timeslonger in life of tool and shorter inmachining time than DIN materials.

•Cutter : M415SP-05R-12

•Insert : SPKN1203EDTR-HP/ TT7070

•V=250m/min f=0.15mm/tooth

•d=2.0mm Center cutting dry

TEST CONDITION

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION

09

■ Weldability

Improved consistency in hardness before/after PWHT.

Distance from the center (mm)

Har

dnes

s (H

v) 500

450

400

350

300

250

200

150500

450

400

350

300

250

200

150

42 6 8 100

as weld

HP4A(D1). Surface

after PWHT

as weld

HP4A(D1). Center

after PWHT

Vick

ers

Har

dnes

s (L

oad:

5kg) 650

600

550

500

450

400

350

300

250

200

150

-25 -20 -15 -10 -5 0 5 10 15 20 25

HP4MA

HP4MA(D2)

BASE HAZ WELD HAZ BASE

WELD HAZ BASE

as weldafter PWHT

after PWHTas weld

HP70

Material

HEMS1A

100 ~ 115

60 ~ 70

120 ~ 135

75 ~ 85

> 17

> 25

> 52

> 50

37 ~ 41

23 ~ 52

Yield Strength(kgf/mm2)

Tensile Strength(kgf/mm2)

Elongation(%)

Reduction of Area(%)

Surface Hardness(HRc)

HP70

•Maintain excellent surface finish

•Uniform hardness throughout the cross section

•Extreme hardness and superior wear resistance

•Excellent electric discharge machinability

HEMS1A

•Excellent corrosion resistance

•Excellent mirror finishing

•High precision

•Uniform hardness throughout the cross section

HP70 / HEMS1A

PLASTIC MOLD STEELS

Characteristics

Quality Properties

■ Vacuum-Degassing Process

Our free cutting steels are vacuum-degassed and forged.

They have 1) excellent cleanliness

2) no pin holes

3) desegregation of alloy elements.

C

HP70

Material

HEMS1A

< 0.25

0.25~ 0.30

> 2.00

≤ 0..30

-

12.00 ~ 12.50

< 0.50

≤ 0.50

Added

Added

Chemical Composition(wt, %)

Ni Cr Mo Special Alloys

■ Chemical Compositions

■ Mechanical Properties

Har

dnes

s(H

Rc)

Har

dnes

s(H

Rc)

Distance from center (mm)

50

45

35

40

30

26

-250 -200 -150 -100 -50 0 50 100 150 200 250

HP70

Cutt

ing

Forc

e(N

)

Cutting Depth (mm)

• Table Moving Speed: 160mm/min.• Face Milling Condition

Cutting Speed: 261m/min.Insert Type: SPKN1504EDRLubricant: No

HP70 HP70

4700C, 5hr

HP70

520 0C, 5hr

HP70

Har

dnes

s(H

v)

Har

dnes

s(H

v)

Distance from the surface (10-2mm) Distance from the surface (10-2mm)

Heat AffectedLayer

•EDM Condition: M/C: Tron150c: Electrode: Copper(8Ø): Surface roughness: Ra4㎛

800120

100

80

60

40

20

800 500

450

400

350

300

250

200

0 2 4 6 8 10 12 14 16 18 20

700

600

500

400

300

0 5 10 15 20 25 30 35 40

00 100 200 300 400

700

600

500

400

300

200

1.0 1.5 2.0

Tens

ile S

tren

gth

(kgf

/mm

2 )

Temperature (0C)

■ Machinability ■ High Temperature Tensile Properties

■ Nitriding Characteristics ■ Electric Discharge Machining

■ Cross-Sectional Hardness Distribution

HEMS1A

0

71

60

50

39

30

50 100 50 0Distance from the surface (mm)

(after Q+T)

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION

11

Har

dnes

s(H

Rc) 65

60

55

50

45

40

35

30

25

100asquenched 200 300 400 500 600

HEMS1AQuenching Temp. : 1025 0C

Tempering Temperature (0C)

■ Tempering Hardness Curve

■ Polishing Workability

Material Remark

HP70

HEMS1A

0.019

Ra.( ) Rmax.( )

0.01

0.167

0.031㎛ Diamond paste use

Clea

nlin

ess

(%)

0.14

0.12

0.10

0.08

0.06

0.04

0.02

0

Wei

ght L

oss

(△g/

g) 0.20

0.15

0.10

0.05

0.00

5% hydrochloric acid

HEMS1A steel, being treated with vacuum-degassingand ESR process, shows an excellent cleanliness.

MaterialQuenching (0C)

1000 ~1050 oil cooling

100 ~ 500 45 ~ 52

23 ~ 33550 ~ 700

Tempering (0C)

Heat Treatment Conditions

HEMS1A

Surface Hardness

(HRc)

HP70 / HEMS1A

PLASTIC MOLD STEELS

■ Heat Treatment

AISI 420 HEMS1A

■ Cleanliness

AISI 420 HEMS1A

■ Corrosion Resistance

Fig. shows workability of polishing and finishing.

Temperature(0C)

Thermalconductivity

(W / m·K)

Specific heat(Cal / g·0C)

Coefficient ofthermal expansion

(10-6 /0C)

HP1A

Material

HP4A(D1)

HP4MA(D2)

HP70

HEMS 1A

100

200

300

400

500

600

100

100

200

300

400

500

600

100

100

200

300

400

500

600

100

100

200

300

400

500

600

100

200

300

400

50.242

48.148

44.799

41.031

-

-

-

-

-

42.287

41.868

40.193

37.263

40.612

40.193

39.356

37.681

33.1176

33.5781

32.9920

31.1917

28.8052

26.0838

22.1482

25.121

26.377

27.214

28.052

-

11.6

11.9

12.4

12.7

0.499

0.513

0.544

0.597

0.644

0.728

0.766

12.89

12.44

13.38

14.01

14.17

14.56

0.116

0.125

0.132

0.138

0.115

0.124

0.131

0.137

0.117

0.126

0.135

0.139

13.76

14.51

15.36

15.81

16.22

16.54

13.87

14.32

14.82

15.58

15.75

16.08

11.82

13.23

14.16

14.64

14.89

15.14

Room temperature

Room temperature

Room temperature

Room temperature

■ Physical Properties

- -

-

-

-

-

-

- -

-

-

-

-

-

- -

-

PHYSICAL PROPERTIES

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION

13

Preliminary HeatTreatment

Machining

Quality Heat TreatmentInspectionShipment

1. Melting > 2. V.S.D(Ingot Making byVacuum Steam Degassing) > 3. E.S.R >

Forging

Melting

VacuumDegassing

Refining Ingot Making inVacuum Condition

Ingot Making

Heating

E.S.R

MANUFACTURING PROCESS

PLASTIC MOLD STEELS

4. Heating > 5. Forging > 6. Heat Treatment > 7. Inspection

Manufacturing Process

GLOBAL NETWORK

Overseas Branches

DOOSAN HEAVY INDUSTRIESAMERICA CORP.Parker Plaza, 10th Floor400 Kelby StreetFort Lee, NJ 07024, U.S.A.Tel 1-201-944-4554Fax 1-201-944-5022, 5053

NEW JERSEY OFFICEParker Plaza, 10th Floor400 Kelby StreetFort Lee, NJ 07024, U.S.A.Tel 1-201-944-4554Fax 1-201-944-5022, 5053

PITTSBURGH OFFICEC/O Westinghouse ElectricCompany, Suite E361B, 4350Northern Pike, Monroeville,PA 15146 U.S.A.Tel 1-412-374-6048Fax 1-412-374-6168

SCHENECTADY OFFICEGeneral Electric Building 33, Room202A One River RoadSchenectady, NY 12345, U.S.A.Tel 1-518-385-5218, 2629Fax 1-518-385-4984

WINDSOR OFFICE20 International DriveWindsor, CT 06095, U.S.A.Tel 1-860-731-6479, 6482Fax 1-860-731-6478

DOOSAN HEAVY INDUSTRIESJAPAN CORP.Mita Kokusai Building, Room 24101-4-28, Mita, Minato-gu,Tokyo 108-0073, JapanTel 81-3-3452-5451~3Fax 81-3-3452-5624

BANGKOK OFFICEM-Thai Tower, 10th FloorAll Seasons Place, 87 Wireless RoadPhatumwan, Bangkok 10330,ThailandTel 66-2-654-0690, 2Fax 66-2-654-0693

BEIJING OFFICEGateway Plaza, Tower B, 19th FloorNo. 18 Xiaguangli, North Road,East Third Ring, Chaoyang District,Beijing 100027, ChinaTel 86-10-8454-7131, 7133Fax 86-10-8484-7139

HANOI OFFICEDaeha Business Center, #1101360 Kim Ma StreetBa Dinh District, Hanoi, VietnamTel 84-4-823-2501, 5Fax 84-4-843-2302

HYDERABAD OFFICEWhite House, #119, Block 36-3-1192/1/1, Kundan BaghBegumpetHyderabad 500 016, IndiaTel 91-40-6613-2444/5Fax 91-40-6613-2447

KOLKATA OFFICETrinity Building, 3G226/1 AJC Bose RoadKolkata 700 020, IndiaTel 91-33-4003-3018Fax 91-33-2289-0576

MUMBAI OFFICEMaker Chambers-V, 1109~1110Nariman Point, Mumbai 400 021,IndiaTel 91-22-2202-6504Fax 91-22-2202-6557

NEW DELHI OFFICELotus Towers 2A, Community CentreNew Friends ColonyNew Delhi 110 065, IndiaTel 91-11-5132-8031Fax 91-11-5132-8039

SHANGHAI OFFICECity Center of Shanghai,Room 2802, 100 Zunyi Road,Changning DistrictShanghai 200051, ChinaTel 86-21-6237-2485~6Fax 86-21-6237-2487

TAIPEI OFFICE51 Keelung Road, Room 704Section 2, Taipei, Taiwan,R.O.C.Tel 886-2-2739-2255(ARS)Fax 886-2-2739-2266

FRANKFURT OFFICEArabella Center, 9th FloorLyoner Strasse 44-48Frankfurt am Main 60528,GermanyTel 49-69-69-5004-0Fax 49-69-69-5004-10

ABU DHABI OFFICEP.O. Box 27767Al Ghaith Tower, Suite 508Hamdan Street, Abu Dhabi,U.A.E.Tel 971-2-627-6273Fax 971-2-627-6274

DUBAI OFFICEP.O. Box 11859Al Serkal Building, Office No. 308Airport Road, Dubai, U.A.E.Tel 971-4-294-4699Fax 971-4-294-9930

KUWAIT OFFICEVilla 15, Street 24, Block 4Sabah Al-Salem Area, KuwaitTel 965-551-8436Fax 965-551-8453

RIYADH OFFICEP.O. Box 9656Riyadh 11423, Saudi ArabiaTel 966-1-419-1920, 1696Fax 966-1-419-1995

TRIPOLI OFFICEP.O. Box No. 7780Tripoli, LibyaTel 218?21?360?8451Fax 218-21-361-0563

DOOSAN WATER R&D CENTERGold & Diamond ParkBuilding No. 6, Office 112Sheikh Zayed RoadP.O. Box 282350, Dubai, U.A.E.Tel 971-4-347-7051Fax 971-4-347-7142

Overseas Subsidiaries

DOOSAN BABCOCK ENERGY LTD.11 The Boulevard, CrawleyWest Sussex, RH10 1UX, U.K.Tel 44-1293-612-888Fax 44-1293-584-816

DOOSAN HYDRO TECHNOLOGY, INC.912 Chad Lane Tampa, FL 33619 ,U.S.A.Tel 1-813-549-0182Fax 1-813-549-0183

DOOSAN HF CONTROLS CORP.1624 West Crosby Road, Suite 124Carrollton, Texas 75006, U.S.A.Tel 1-469-568-6526, 6557Fax 1-469-568-6589

DOOSAN IMGB104 Berceni Road Bucharest 4, RomaniaTel 40-21-301-2602Fax 40-21-301-2701

DOOSAN BABCOCK ENGINEERING &SERVICES INDIA PVT. LTD.DLF Building No. 8, 3rd FloorDLF Cyber City Phase IIGurgaon 122 002, Haryana, IndiaTel 91-124-439-8200Fax 91-124-414-7006

DOOSAN PROJECTS INDIA PVT. LTD.322 Solitaire Corporate Park, ChakalaAndheri Kurla Road, Andheri (East)Mumbai 400 093, IndiaTel 91-22-4097-0500Fax 91-22-4097-0599

DOOSAN HEAVY INDUSTRIESVIETNAM CO., LTD. [DOOSAN VINA]No. 1 An Duong Vuong StreetQuangngai City, Quangngai ProvinceVietnamTel 84-55-713-001~7Fax 84-55-713-008

HAN-VIET HEAVY INDUSTRY &CONSTRUCTION CORP. [HANVICO]933 Ton Duc Thang StreetHong Bang District, Hai Phong,VietnamTel 84-31-371-2720Fax 84-31-712-714~5

CEYLON HEAVY INDUSTRIES &CONSTRUCTION CO., LTD. [CHICO]Oruwala Athurugiriya, Sri LankaTel 94-114-440031~2Fax 94-114-440030

HANJUNG POWER LTD.P.O. Box 2803, Boroko, NCDPort Moresby, Papua New GuineaTel 675-320-0529Fax 675-321-2984

Doosan Heavy Industries & Construction Co., Ltd. www.doosanheavy.com

SEOUL OFFICE HEAD OFFICE AND CHANGWON PLANT1303-22, Seocho-Dong, Seocho-Gu. Seoul 137-920, 555, Guigok-dong, Changwon, Korea (C.P.O Box 1826, Seoul Korea) Gyeongsangnam-do, 641-792, KoreaTel. 82-2-513-6114, Fax. 82-2-513-6200 Tel. 82-55-278-6114, 7114 Fax. 82-55-264-5551,5552