The FASTEEL project deals with the upscaling and validation of the new generation of innovative high thermal conductivity tool steels of Rovalma. The main application targets of FASTEEL grades are tools, dies, moulds and inserts for hot forming production processes, especially die casting of light alloys, plastic injection moulding, hot stamping of Advanced High Strength Steels and composite forming. In these processes, the dies fulfil two important functions: (1) shaping of a material into the desired component geometry, (2) being a heat transfer medium. The shaped components are solidified and cooled by extracting the heat previously used to melt (in the case of die casting and plastic injection moulding) or to preheat (in the case of hot stamping) the component material. When the melt or preheated material is introduced into the dies, the heat is removed from the components by the corresponding forming tools. The heat is then transferred through the tool material to the cooling medium inside the cooling lines of the tools. Tool material thus functions as a bridge between the cooling medium and the shaped component inside the die. The flux of heat crossing this bridge is determined by the thermal conductivity (TC) of the tool material. As the rate of heat transfer depends on the TC of the tool material, the low TC of traditionally used tool steels limits the productivity of these hot forming processes and the feasibility of making thinner and more complex components. ROVALMA has invented technology to make tool steels with the required mechanical properties for these tools with very high TC. There is an enormous market potential for these tool steels, however manufacturing of a tool is a costly process and associated with other important requirements such as standardization, conformance control, certification, heat treatment requirements, machinability, weldability, surface treatability, safety instructions for the handling. In addition to the combination of high TC and high mechanical properties, FASTEEL grades feature another innovative feature compared to conventional tool steels, as they are supplied in an easy-to-machine state and ready for precipitation hardening through a single low temperature cycle, or in pre-hardened condition and with the hardness and other mechanical properties adjusted to the typical application requirements of the different forming processes. These features shorten the tool manufacturing time and cost considerably, allow to realize the benefits of a homogenous property distribution throughout the tool, with the corresponding positive impacts on produced component quality and durability of the dies themselves. Thanks to the work carried out, the project objectives have been achieved with success: the FASTEEL grades have been up-scaled, optimized, pilot-tested and are now ready for market launch.
