Why was high performance steel developed?

Subset of tool steels

High-speed steel (HSS or HS) is a subset of tool steels, commonly used as cutting tool material.

It is often used in power-saw blades and drill bits. In addition, it is often used in bowl gouges and skew for woodturning.[1] It is superior to the older high-carbon steel tools used extensively through the 1940s in that it can withstand higher temperatures without losing its temper (hardness). This property allows HSS to cut faster than high carbon steel, hence the name high-speed steel. At room temperature, in their generally recommended heat treatment, HSS grades generally display high hardness (above Rockwell hardness 60) and abrasion resistance (generally linked to tungsten and vanadium content often used in HSS) compared with common carbon and tool steels. There are several different types of HS steel, such as M42 and M2.[1]

History

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In 1868 English metallurgist Robert Forester Mushet developed Mushet steel, considered the forerunner of modern high-speed steels. It consisted of 2% carbon, 2.5% manganese, and 7% tungsten. The major advantage of this steel was that it hardened when air cooled from a temperature at which most steels had to be quenched for hardening. Over the next 30 years, the most significant change was the replacement of manganese with chromium.[2]

In 1899 and 1900, Frederick Winslow Taylor and Maunsel White (né Maunsel White III; 1856–1912; grandson of Maunsel White; 1783–1863), working with a team of assistants at the Bethlehem Steel Company at Bethlehem, Pennsylvania, US, performed a series of experiments with heat treating existing high-quality tool steels, such as Mushet steel, heating them to much higher temperatures than were typically considered desirable in the industry.[3][4] Their experiments were characterised by a scientific empiricism in that many different combinations were made and tested, with no regard for conventional wisdom or alchemic recipes, and detailed records kept of each batch. The result was a heat treatment process that transformed existing alloys into a new kind of steel that could retain its hardness at higher temperatures, allowing much higher speeds and rate of cutting when machining.

The Taylor-White process[5] was patented and created a revolution in machining industries. Heavier machine tools with higher rigidity were needed to use the new steel to its full advantage, prompting redesigns and replacement of installed plant machinery. The patent was contested and eventually nullified.[6]

The first alloy that was formally classified as high-speed steel is known by the AISI designation T1, which was introduced in 1910.[7] It was patented by Crucible Steel Co. at the beginning of the 20th century.[2]

Although molybdenum-rich high-speed steels such as AISI M1 had seen some use since the 1930s, it was the material shortages and high costs caused by WWII that spurred development of less expensive alloys substituting molybdenum for tungsten. The advances in molybdenum-based high speed steel during this period put them on par with, and in certain cases better, than tungsten-based high speed steels. This started with the use of M2 steel instead of T1 steel.[2][8]

Types

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High speed steels are alloys that gain their properties from a variety of alloying metals added to carbon steel, typically including tungsten and molybdenum, or a combination of the two, often with other alloys as well.[9] They belong to the Fe–C–X multi-component alloy system where X represents chromium, tungsten, molybdenum, vanadium, or cobalt. Generally, the X component is present in excess of 7%, along with more than 0.60% carbon.

In the unified numbering system (UNS), tungsten-type grades (e.g. T1, T15) are assigned numbers in the T120xx series, while molybdenum (e.g. M2, M48) and intermediate types are T113xx. ASTM standards recognize 7 tungsten types and 17 molybdenum types.[10]

The addition of about 10% of tungsten and molybdenum in total maximises efficiently the hardness and toughness of high speed steels and maintains those properties at the high temperatures generated when cutting metals.

A sample of alloying compositions of common high speed steel grades (by %wt)[11][12] (impurity limits are not included) Grade C Cr Mo W V Co Mn Si T1 0.65–0.80 4.00 - 18 1 - 0.1–0.4 0.2–0.4 M1 0.80 4 8 1.5 1.0 - - - M2 0.85 4 5 6.0 2.0 - - - M7 1.00 4 8.75 1.75 2.0 - - - M35 0.92 4.3 5 6.4 1.8 5 - 0.35 M42 1.10 3.75 9.5 1.5 1.15 8.0 - - M50 0.85 4 4.25 .10 1.0 - - -

Molybdenum High Speed Steels (HSS)

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Combining molybdenum, tungsten and chromium steel creates several alloys commonly called "HSS", measuring 63–65 Rockwell "C" hardness.

M1

M1 lacks some of the red-hardness properties of M2, but is less susceptible to shock and will flex more.

M2

M2 is the "standard" and most widely used industrial HSS. It has small and evenly distributed carbides giving high wear resistance, though its decarburization sensitivity is a little bit high. After heat treatment, its hardness is the same as T1, but its bending strength can reach 4700 MPa, and its toughness and thermo-plasticity are higher than T1 by 50%. It is usually used to manufacture a variety of tools, such as drill bits, taps and reamers. 1.3343 is the equivalent numeric designation for M2 material identified in ISO 4957.

M7

M7 is used for making heavier construction drills where flexibility and extended drill life are equally important.

M50

M50 does not have the red-hardness of other grades of tungsten HSS, but is very good for drills where breakage is a problem due to flexing the drill. Generally favored for hardware stores and contractor use. It is also used in high-temperature ball bearings.

Cobalt High Speed Steels (HSS)

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The addition of cobalt increases heat resistance, and can give a Rockwell hardness up to 70 Min.[13]

M35

M35 is similar to M2, but with 5% cobalt added. M35 is also known as Cobalt Steel, HSSE or HSS-E. It will cut faster and last longer than M2.[14]

M42

M42 is a molybdenum-series high-speed steel alloy with an additional 8% cobalt.[13] It is widely used in metal manufacturing industries because of its superior red-hardness as compared to more conventional high-speed steels, allowing for shorter cycle times in production environments due to higher cutting speeds or from the increase in time between tool changes.[14]

Forming

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HSS drill bits formed by rolling are denoted HSS-R. Grinding is used to create HSS-G, cobalt and carbide drill bits.[15]

Applications

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The main use of high-speed steels continues to be in the manufacture of various cutting tools: drills, taps, milling cutters, tool bits, hobbing (gear) cutters, saw blades, planer and jointer blades, router bits, etc., although usage for punches and dies is increasing.

High speed steels also found a market in fine hand tools where their relatively good toughness at high hardness, coupled with high abrasion resistance, made them suitable for low speed applications requiring a durable keen (sharp) edge, such as files, chisels, hand plane blades, and damascus kitchen knives and pocket knives.[citation needed]

High speed steel tools are the most popular for use in woodturning, as the speed of movement of the work past the edge is relatively high for handheld tools, and HSS holds its edge far longer than high carbon steel tools can.[citation needed]

See also

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References

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High Speed Steel specifications have been developed over many years primarily for use in high speed cutting applications, but also for the production of tools and dies. The characteristics vary with each grade, but common properties include high resistance to wear and excellent toughness. High speed steel grades also have a high resistance to softening at elevated temperatures up to 500°C, this makes them perfect for use at high speeds, hence the name.

With heat treatment these steels can achieve a high Rockwell hardness, for example, M2 high speed steel is commonly hardened to 64HRc, whereas M42 can be hardened up to 70HRc, though commonly hardened to 66-68HRc.

Chemical composition for high speed steel grades combine some or all alloying elements of carbon, chromium, molybdenum, vanadium, tungsten and cobalt. Grades with a carbon, vanadium and tungsten combination can offer supreme wear resistance. Cobalt grades offer improved hot hardness and tempering resistance, but lowers toughness.

History

In 1868 Robert Mushet invented a self-hardening/air hardening steel known as Mushet Steel or R Mushets Special Steel. This was the first known special steel which when forged and cooled acquired a degree of hardness. It was extensively used for engineering tools and at the time was patented and its chemical composition kept a secret. We now know that an 8% tungsten content was key to the steels characteristics. In 1870 Samuel Osborn & Company of Sheffield, UK purchased the rights to manufacture the steel for mass production.

At the turn of the nineteenth century American, Frederic Taylor and Brit, Maunsel White, working in America at the Bethlehem Steel Company in Pennsylvania, did numerous tests and experiments on Mushet Steel to understand more about its characteristics. During these experiments they discovered that adding a 3.8% chromium to the 8% tungsten steel enabled it be quenched and tempered at a high temperature (close to the melting point of steel). In service the it could work at much faster speeds than Mushet Steel. The name given to this was High Speed Steel.

T1 was one of the first mass produced high speed steels. It was developed and made from 1910 and at that time patented by Crucible Steel Co, New Jersey, USA. The tungsten molybdenum high speed steel M2 was invented by W Breelor in the USA in 1937.

In subsequent years many new high speed steel grades were developed. In the UK a number of special steel producers (predominantly in Sheffield) manufactured numerous High Speed Steel, as well as Tool Steel specifications. It was commonplace at this time for each manufacturer to give each grade a unique company steel brand name. Samuel Osborn & Company were a good example of this, proud to use the name of Mushet in their high speed steel grades, for example;

Samuel Osborn Brand Name       AISI      BS4659*
Double Mushet ND                           T1           BT1
Triple Mushet GZ                               T4           BT4
Mushet MKK                                       M2          BM2
Mushet Special VG                           M15        BM15
*(introduced in 1971)

Common High Speed Steel Specifications

The numerous brand names given to tool and high speed steels was confusing for buyers at the time. In 1971 the British Standards Institution drew up new standards for all the main types of tool and high speed steels used in the UK, known as BS4659. Overtime the range of high speed steel being produced has reduced. Currently the most popular grades are M2, M35 and M42 which are available in round bar, flat bar and plate.

M2 HSS

With its tungsten molybdenum composition M2 high speed steel offers high wear resistance after hardening. With better toughness and good cutting powers it has now replaced T1 as the most popular grade of high speed steel. Nowadays T1 is rarely produced or stocked in the UK.

M35 HSS

The addition of cobalt to M35 give it better heat resistant characteristics than M2.

M42 HSS

With a high hardness (up to 70HRc) and superior hot hardness tools made from M42 tools give excellent cutting performance in service.

Applications

High speed steel specifications are commonly used for tool bits (add link), cutting tools, taps, drills, cutters and bandsaw blades. With their high hardness and high abrasion resistance high speed steels are often used in tooling applications for components such as punches and dies.