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JOURNAL OF IRON AND STEEL RESEARCH, INTERNATIONAL. 2006, 13(5) : 53-59

Effect of Alloying Elements on Thermal Wear of

Cast Hot-Forging Die Steels
WANG Shu-qi' , C H E N Kang-min' , CUI Xiang-hong' , JIANG Qi-chuan' , HONG Bian'
(1. School of Materials Science and Engineering, Jiangsu University, Zhenjiang 212013, Jiangsu, China;
2. School of Materials Science and Engineering, Jilin University, Changchun 130025, Jilin, China)

Abstract: The effect of main alloying elements on thermal wear of cast hot-forging die steels was studied. The wear
mechanism was discussed. T h e results show that alloying elements have significant influences on the thermal wear of
cast hot-forging die steels. T h e wear rates decrease with an increase in chromium content from 3 % to 4 % and mo-
lybdenum content from 2 % to 3 % , respectively. With further increase of chromium and molybdenum contents,
chromium slightly reduces the wear resistance and molybdenum severely deteriorates the wear resistance with high
wear rate. Lower vanadiumicarbon ratio (1. 5-2. 5) leads to a lower wear resistance with higher wear rate. With an
increase in vanadium/carbon ratio, the wear resistance of the cast steel substantially increases. When vanadium/car-
tion ratio is 3 , the wear rate reaches the lowest value. The predominant mechanism of thermal wear of cast hot-forg-
ing die steels are oxidation wear and fatigue delamination. The F e 2 0 3 and Fe,O, or lumps of brittle wear debris are
formed on the wear surface.
Key words: hot-forging die; cast steel; alloying element; thermal wear; mechanism

Hot-forging dies play an important role in some
industries, such as automobiles, general machinery,
farm machinery, and so on. Cast hot-forging dies as
a new alternative for production of hot-forging dies
have many advantages: high utilization ratio of ma-
terials, low finish allowance, short process time and
regenerative use of obsolete dies. Cast hot-forging
dies have been studied and applied since the 1940s.
Now cast hot-forging dies are manufactured in a
large scale and utilized widely in some developed
But lives of domestically made cast
hot-forging dies should be improved further because
of the lower wear resistance resulted from unreason-
able alloying composition design. Alloying composi-
tion design of the cast steels is the key factor deter-
mining the life of the cast hot-forging dies. It is
found that the long-life dies always have high wear
resistance. Researches on the alloying composition
design of cast hot-forging die steels are sparsely re-
_______
Foundation Item: Item Sponsored by Early-Term Key Technology of Industrialization and Whole Set Equipment From Plan Committee of China
(1999317), 863 Project of China (2002AA331180), and Project of Key Lab of Universities in Jiangsu Province of China
(Kjsmcx04004)
Biography: WANG Shu-qi(l962-), Male, Doctor, Professor;
ported. T h e cast die steels used earlier have the
same composition as the commercial die steels, for
instance, 5CrNiMo, 5CrMnMo, and H13. Later,
the compositions of cast hot-forging die steels were
slightly changed based on the commercial die steels,
by the addition of some alloying elements. T h e mod-
ified H13 cast steel is developed by the addition of
RE or Ni to improve some propertiesi5961-.It must be
noted that these cast die steels usually have unrea-
sonable alloying composition design, with no ideal
foundry properties and mechanical properties. T h e
special composition designs for as-forged steel are
not suitable for as-cast steel. T h e characteristics of
as-cast steels are different from as-forged steels.
T h e alloying composition design for cast die steel
must take advantage of the superior properties of
cast steels : high thermal stability, high resistance to
thermal fatigue and thermal wear with avoiding low
plasticity. T h e purpose of the research is to study
E-mail: shuqi-wang@ujs. edu. cn; Revised Date: September 6 , 2005
 * 54 Journal of Iron and Steel Research, International
the influences of main alloying elements on thermal
wear for the alloying composition design of cast hot-
forging die steels. T h e mechanism of thermal wear
is also discussed.
1 Experimental Procedure
T h e raw materials for cast hot-forging die steels
were melted in a 250 kg medium frequency induction
furnace with non-oxidation method. A t 1 550 'C,
the melt was deoxidized with aluminum, then
poured. T h e modified agents containing R E , titani-
um, and niobium were put in a ladle for modification
of the melt and finally the hedge sample was cast.
T h e steel was austenitized a t 1 020 'C for 1 h and
quenched in oil to obtain the complex structure inclu-
ding martensite and bainite, then tempered at 440 "Cor
600 %.
T h e thermal wear test was carried out on an
MG-2000 type pin-disk high-temperature wear test-
er. T h e test norms were specified as dry friction,
and the test conditions are: test temperature 400 'C ,
load 100 N , sliding speed 2 m / s , and total sliding
distance 1. 8 X lo3 m. T h e pins are made of cast die
steels with dimensions of $6 m m X 1 2 mm and disks
of CrlZMoV, 58 H R C with dimensions of $70 m m X
8 mm.
Before test, pins and disks were polished and
degreased. T h e pin specimens were cleaned with ac-
etone and dried before and after the test for weighing
the wear loss by the balance with an accuracy of
0. 01 mg. T h e wear rate, W,, is calculated in term
of the formula:
W,=AV/p d (1)
where a V is wear volume loss (wear weight loss/
density); p is load; and d is sliding distance. T h e
morphology, composition, and structure of the wear
surface and debris were analyzed with an AMRA-
lOOOB type S E M with supplement E P M A and a D/
Max-2500/pc type X-ray diffractometer. T h e hard-
ness was measured on an HRC150 type durometer.
2 Results and Discussion
2. 1 Effect of alloying elements on thermal wear rate
T h e effects of main alloying elements on the
thermal wear rate are shown in Fig. 1. T h e cast hot-
forging die steel is typically Cr-Mo-V alloy steel.
Chromium content, molybdenum content, and vana-
dium/carbon ratio are the important alloying fac-
tors. It is obvious in Fig. 1 that chromium content,
Vol. 13
molybdenum content, and vanadium/carbon ratio
have significant influences on wear rate.
With an increase in chromium content, the wear
rate apparently decreases. But as chromium content rea-
ches 5 ,% , the wear rate slightly increases [Fig. l (a)].
T h e hardness of the cast steels tempered at 440 "C
and 600 'C are 45 - 48 H R C and 38 - 32 H R C , re-
spectively. A n increment in chromium content re-
sults in a slight reduction of the hardness of the cast
steel tempered at 440 C , whereas hardness reduc-
tion of the cast steel is obvious when tempered at
600 'C. Although the steels tempered at 440 'C and
600 'C have different hardness, their wear rates are
approximately similar.
With an increase in molybdenum content, the
hardness of the cast steel remains unchanged. T h e
hardness of the cast steels tempered at 440 'C and
600 "Care 4 5 - 4 4 H R C and 40-39 H R C , respec-
tively. But the wear rate first decreases, and then
increases [Fig. 1 ( b ) ] . T h e wear rate of the cast
steel with molybdenum content of 3 % is the lowest.
Excessive molybdenum obviously deteriorates the
wear resistance with high wear rate.
The influence of vanadium content on thermal wear
rate is shown in Fig. 1 (c). Vanadium is a strong car-
bideforming element. In steel, vanadium preferential-
ly combines with carbon to form V, C,. T h e amount
of V,C? is dependent on the relative amount of vana-
dium and carbon, i. e. , the vanadium/carbon ratio.
Therefore, the effect of vanadium/carbon ratio on
wear rate reveals the comprehensive function of car-
bon and vanadium. With increasing vanadium/car-
bon ratio, the hardness variations of the cast steels
tempered at 440 O C and 600 "C follow almost the
same rule that the hardness first increases and then
decreases. When vanadium/carbon ratio is 3, the
hardness of the cast steels reaches the climax with
47- 49 HRC. T h e steel tempered at 600 'C has a
high wear resistance than that tempered at 440 "C.
Consequently, the wear resistance has no corre-
sponding relation with hardness. High hardness
does not always mean high wear resistance. T h e cast
steels tempered at different tempering temperatures
exhibit different variation rules of the wear rate. For
the steel tempered at 440 "C,the wear rate first
slightly increases with variation of vanadium/carbon
ratio from 1. 5 to 2. 5, then arrives at its lowest
point when vanadium/carbon ratio equals 3 . 0 , after-
wards slightly increases. With an increase in vanadi-
um/carbon ratio, t h e wear rate decreases till to the
No. 5 Effect of Alloying Elements on T h e r m a l Wear of Cast H o t - F o r g i n g Die Steels * 55 *

50

L
16 2

12

2 3 .1 1.6 2.0 2.5 3.0 3.5

Chromium rontrnIPh Molybdenum contenlPh Vanadinndrarbon ratio

1-Wear rate of steel tempered a t 440 C ; 2--Wear rate of steel tempered at 600 C ;
3-Hardness of steel tempered at 440 'C ; 4 Hardness of steel tempered a t 600 ~C
Fig. 1 Effect of alloying element on thermal wear rate of cast hot-forging die steels

the lowest value when vanadium/carbon ratio is
3. 0 , and then slightly increases for the cast steel
tempered at 600 'C.
2. 2 SEM morphology of wear
SEM photographs of the wear surfaces of the
cast die steels with different compositions are shown
in Fig. 2 to Fig. 4. T h e alloying elements have obvi
ous influences on the morphologies of wear surfaces.
It is obvious that there are two different regions on
the wear surface: the delamination region and the
non-delamination region. T h e area and morphology
of delamination region vary with the kind and amount of
alloying elements.
T h e effect of chromium content on the wear
morphology is revealed in Fig. 2. With an increase in
chromium content from 3 % t o 4 % , the delamination
region decreases. With further increase in chromium
content from 4 % t o 5 % , the delamination region
starts to increase again. Meanwhile, the morpholo-
gy of the delamination region changes from large
lump delamination t o small lump delamination, and
finally much flocky granula appears in the delamina-
tion region.
T h e effect of molybdenum content on the wear
morphology is obvious in Fig. 3. With an increase in
molybdenum content from 2 % to 3 % , the delamina-
tion region decreases. T h e morphology of delamina-

( a ) , ( b ) Chromium content 3 % ; ( c ) , ( d ) Chromium content 4. 0 % ; ( e l , ( f ) Chromlurn content 5. 0 %

Fig. 2 SEM images of thermal wear surface of cast die steel with different chromium content and molybdenum content of 2%
 * 56 * Journal of Iron and Steel Research, International Vol. 13

( a ) , ( b ) Molybdenum content 2 % ; ( c ) , (d) Molybdenum content 3 % ; ( e l , ( f ) Molybdenum content 4 %

Fig. 3 SEM images of thermal wear surface of cast die steel with chromium content of 3 % and different molybdenum content

tion region changes from large lump to granula.
With further increase in molybdenum content from
3 % t o 4%, the delamination region starts t o in-
crease when flocky granula appears on it.
Fig. 4 shows the variation of wear morphology
of the cast steel with different vanadiumicarbon ra-
tio. When vanadiumicarbon ratio is 1. 5-2. 5 , there
are more, larger delamination regions with much
flocky granula. As vanadiumicarbon ratio increases
to 3. 0 - 3. 6 , the area of delamination region with
granula decreases.
2.3 Mechanism of thermal wear
In atmosphere, high surrounding temperature
and friction heat result in oxidation of the wear sur-
face of cast die steels, and the oxidation speed dur-
ing wear procedure is higher than that of static oxi-
dationC7. The EDS analysis of the wear surface is
shown in Fig. 5. High oxygen content is contained on
the wear surface. Through semi-quantitative analy-
sis, the oxygen content on the wear surface reaches
24. 38 %. T h i s is typically characteristic of oxidation
Wearia-121 . Phase analysis by X-ray diffraction reveals

( c ) , ( d ) Vanadium/carbon ratio 3. 0 ;
( a ) , ( b ) Vanadium/carbon ratio 2. 5 ; ( e ) , ( f ) Vanadiumjcarbon ratio 3. 6
Fig. 4 SEM images of thermal wear surface of cast die steel with different vanadium/carbon ratio
No. 5 Effect of Alloying Elements on Thermal Wear of Cast Hot-Forging Die Steels
845
I
0 2 4 G
EnergykeV
Fig. 5 EDS analysis of wear surface of cast die steel
that the oxides are FezO3 and Fe30, (Fig. 6 >. T h e
morphology and composition of the wear debris are
shown in Fig. 7. It is obvious that the brittle lump
wear debris contains more oxygen. T h e largest di-
ameter of the debris reaches 60 pm.
A layer of oxide is easily formed on the wear
surface owing to the elevated temperature resulted
from the surrounding temperature and friction heat.
It has been reported that F e 2 0 3 and Fe,O, can pro-
tect from ~ e a r I ' ~ ~ l jTherefore
'. the wear rate de-
creases. Meanwhile, the oxide film is easily delami-
nated from the matrix metal in the case of heavy
load, because of the brittleness of oxide. Some de-
laminated oxide films fall off from the wear surface
in the form of lump debris. T h e residual delamina-
ted oxides are ground into granular or flocky granu-
lar oxides, which were retained in the delaminated
region. Granular oxides retained in the delaminated
region have a large binding force to prevent wear to
some extent. Flocky oxides float on the delaminated
region and easily fall off from the wear surface, thus
increase the wear rate. In most cases, oxide delami-
nation is attributed to low thermal strength of the
matrix metal. T h e steel with low thermal strength
cannot support oxide film. T h e force leads to d e -
formation of the matrix and separates it from the o x -
ide film. High thermal strength is the key factor of
keeping the binding between the steel and the oxide
film. T h e steel with high thermal strength can s u p -
port the oxide film to protect the wear surface from
wear. T h e thermal wear resistance is closely related
to the chemical compositions, microstructures, and
properties of steel. As a result, the cast hot-forging
steel with high wear resistance needs an optimal al-
loying design.
After delamination of oxide, the steel in the de-
57
2 500
I Fe
2 000
-
rE
1 500
Y
2 1000
c
-S
e
500
8 10
0
28/(")
Fig. 6 XRD pattern of wear surface of cast die steel
lamination region continues to oxidize. T h u s , oxida-
tion and delamination occur alternatively till equilib-
rium is reached. T h e wear rate is dependent on the
amount of delamination oxides falling off from the
friction system.
T h e chromium, molybdenum, and vanadium
are the dominant alloying elements of cast hot-forg-
ing die steel. T h e steel has higher resistance to tem-
pering and secondary hardening at 520 CI']. During
wear process, the microstructure and properties of
the cast steel change because of the higher tempera-
ture, which depends on the relative amount of allo-
ying elements including chromium, molybdenum,
and vanadium.
More chromium in a-Fe increases the thermal
strength. a-Fe in the steel tempered at 440 'C con-
tains more chromium than that tempered at 600 %.
In this case, the steels tempered a t 440 "Chave low-
er wear rate than that tempered at 600 'C. For the
steels tempered a t 440 "C, with a n increase in chro-
mium content from 3% to 4%, the chromium con-
tent in a-Fe increases in order to increase the thermal
strength for supporting the oxide film and prevent
delamination. As a result, the wear rate decreases.
Rut excessive chromium ( 5 ,%) results in the forma-
tion of a large quantity of Cr7C3and CrZ3C, , and a
reduction of chromium in a-Fe. These types of car-
bides having lower thermal stability are easy to
coarsen. This leads t o a decrease in the thermal
strength. Consequently, the oxide film is liable to
delaminate and the wear rate increases. Similarly,
for the steel tempered a t 600 C , Cr,C3, and Cr,,C,
are completely precipitated. Therefore, excessive
chromium ( 5 % ) can be used t o strengthen a-Fe to
some extent, so the wear rate continues to decrease
 . 58 - Journal of Iron and Steel Research, International
Fig. 7 SEM images and EDS analysis of wear debris of cast die steel
slightly. But the bad function of excessive chromium
starts to act.
With an increase in molybdenum content from
2 % to 3 % , molybdenum partly solubilizes in a-Fe
and partly precipitates in the form of Mo2C with
high hardness and thermal stability. T h e thermal
strength of steel can be enhanced. T h e wear resist-
ance increases with a low wear rate. However, in
the case of excessive molybdenum (4%), M o 2 C is
converted to Mo6C with low thermal stability. Addi-
tionally, this type of carbide segregates in the aus-
tenite grain boundary and martensite grain bounda-
r y , which results in the brittleness of the steel"".
T h e oxide film on the wear surface in this steel is li-
able to delaminate with a high wear rate. When the
steel is tempered at 440 'C, Mo6C starts to precipi-
tate with less quantities. When tempering tempera-
ture is increased t o 600 'C, much Mo6C appears.
Consequently, excessive molybdenum is extremely
harmful to the wear resistance of the steel tempered
a t 600 'c.
With increasing vanadium content, carbon in KFe
decreases and V, C,increases. As vanadium/carbon ra-
tio increases from 1. 5 t o 3. 6 , the carbide V, C, can
wholly precipitate for the steel tempered at 600 'C.
T h e steel with more V,$C, has high thermal stabili-
ty. For the steel tempered a t 440 C , the amount of
V,,C, is relatively less. Consequently, the steel tem-
pered at 600 'C has lower wear rate than that tem-
pered at 440 'C. It is found that the variation of
wear rate is similar to that of hardness. With in-
creasing vanadium/carbon ratio, V, C, increases and
this leads to the increase of thermal strength and
thermal stability, thus providing firm support for
the oxide film. I t is helpful for reducing the delami-
nation of the oxide, so the wear rate decreases.
When vanadium/carbon ratio exceeds 3 , vanadium
partly solubilizes in a-Fe. T o some extent, the
Vol. 13
1 200
IFr
strength of the steel is reduced, and hence, the wear
rate increases slightly. T h e harmful tendency of ex-
cessive vanadium for wear resistance can be found.
3 Conclusions
( 1) Chromium content, molybdenum content,
and vanadium/carbon ratio have significant influ-
ences on the wear rate of cast hot-forging die steel.
T h e wear rate apparently decreases with an increase
in chromium content from 3 % t o 4%, and an in-
crease in molybdenum content from 2 % to 3 % , re-
spectively. But, a s chromium content reaches 5 ,%,
the wear rate slightly increases. Excessive molybde-
num (4%) obviously deteriorates the wear resist-
ance with a high wear rate. T h e steels with lower
vanadium/carbon ratio ( 1. 5 - 2. 5 ) have a higher
wear rate. With increasing vanadium/carbon ratio,
the wear rate decreases. As vanadium/carbon ratio
reaches 3 , the wear rate decreases to its lowest
point.
( 2 ) T h e predominant mechanism of thermal
wear of cast hot-forging die steel are oxidation wear
and fatigue delamination. T h e oxides from wear
process are F e 2 0 , and F e 3 0 4 , and lump of brittle
debris exists on the wear surface.
( 3 ) T h e wear rate is dependent on the amount
of delamination oxide falling off from the friction
system.
(4) T h e oxide delamination is attributed to the
low thermal strength of the matrix metal. T h e steel
with a high thermal strength can support the oxide
film and prevent delamination. T h e cast hot-forging
steel with a high wear resistance needs an optimal
alloying design.
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