School of engineering

ENGG*6290*02– Advanced Engineering

Materials

Project report

Topic: - High Speed Steel

Guided By: - Dr. Saha Jhantukumar, PhD

Prepared by
Akshay Dangariya (1202530)

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 Contents
I. Abstract

II. Introduction and background information

III. Synthesis/manufacturing

IV. Properties/characterization

V. Applications

VI. Conclusions

VII. References

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Abstract
High speed steels (HSS) are multicomponent alloys with a ferrous base, Fe-C-X, where X is a
set of alloying elements, primarily W, Cr, or V, Mo, and Co. Due to their ability to maintain
the highest level of hardness when cutting metals at a high rate, these steels are mostly
utilised for cutting tools. High speed steels have a dendritic interdendritic web of eutectic
carbides surrounding them in their as-cast microstructure. Even under extremely quick
cooling rates of up to 106 K s-1, they are seen. In this paper I am further explaining about the
how high speed steel is synthesise and manufactured over time. The manufacturing process of
the high speed steel is like a any other manufacturing process in industry, the equipment is
used for the high speed steel is conveyor belt, heaters, pumps, boilers and reboilers, exhausts,
motors, heat recovery units, pipes, cranes, and other standard machines, just like any other
industrial facility. I am also discussing about the some of the processing step of the high
speed steel in the manufacturing industry and effect of those steps on the high speed steel. In
addition, I also given the concise description on the safety and sustainability of the high speed
steel. In the synthesis properties of the high-speed steel, tungsten will increase the red
hardness of the HSS, molybdenum will decrease the solidification temperature of HSS,
chromium will raise the hardenability, oxidative stability and corrosion resistance of HSS,
vanadium will raise the hardenability, oxidative stability and corrosion resistance of HSS and
cobalt will boost high speed steel's secondary hardness, high temperature hardness, and
thermal conductivity. There are few characterizations technique also I am discussing in this
paper like Hardness testing by Vickers hardness testing, Scanning Electron Microscope
(SEM) Analysis, Impact Testing. At end of this paper, I will give the three intended
application of the high speed steel and the claims of those application.

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Introduction and background information

 History of high speed steel

 A very longer history exists for both high-speed steels and their heat treatments.
 Even though the second half of the nineteenth century saw the beginning of the
creation of HSS, there is historical evidence of the production of steel grades with a
comparable composition earlier. Some of these date back to the 13th century BC in
China, the 350 BC creation of wootz steel in India, and the 540 AD and 900 AD
manufacturing of Damascus & Japanese layered steel blades.
 After crucible steel was discovered in 1740, Forester Mushet created Mushet steel in
1868, which is regarded as the precursor to current high speed steels. It had 2.5% Mn,
7% W, and 2% C. This steel's main benefit is that it still hardened while air cooled
from the a temperature where most steels required quenching in order to harden. The
biggest change over the following 30 years was the switch from manganese to
chromium.
 Bethlehem Steel Company in Bethlehem, Pennsylvania, in 1899 & 1900, Maunsel
White & Frederick Winslow Taylor conducted a number of experiments only with
heat treating of high-quality tool steels that already existed, like Mushet steel, heating
them far too much extreme temps than were typically thought to be desirable in the
industry. They worked with a team of assistants. Their research was characterised by
a scientific realism in that numerous combinations were created and tested without
consideration for received wisdom or alchemical formulas, and thorough records of
each batch were kept. The eventual product was just a heat treatment procedure that
changed current alloys into a new type of steel with the ability to maintain its
hardness at greater temperatures, enabling far higher machining speeds and depths of
cut.
 The Taylor-White technique, which was patented, revolutionized the machining
industries & really called for completely new, heavier industrial equipment designs in
order to make the most of the new steel. The patent was vigorously disputed and
ultimately declared invalid.
 The AISI code T1, which has been adopted in 1910, is used to refer to the first alloy
that's been formally categorised as high speed steel. Early in the 20th century,
Crucible Steel Co. obtained a patent for it.
 Although high speed steels with a high molybdenum content, such as AISI M1, have
been in use since 1930s, World War II-era shortages & high raw material costs
prompted the creation of alloy compositions in which molybdenum replaced tungsten
to provide less expensive steel. During this time, molybdenum-based high speed
steels advanced to the point where they were competitive with and occasionally
superior to tungsten-based high speed steels. This began with the substitution of T1
steel by M2 steel (a sulfurized form of M1).

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 How high speed steel is discovered?
 American Frederic Taylor and British Maunsel White, who were employed by the
Bethlehem Steel Company in Pennsylvania at the turn of the nineteenth century,
conducted various tests and experiments on Mushet Steel to learn more about its
properties. During these tests, it was revealed that the 8% tungsten steel could be
quenched and tempered at a high temperature by adding a 3.8% chromium. When in
use, it could perform tasks far more quickly than Mushet Steel. High Speed Steel was
the name given to this material.

 Currently, M2, M35, and M42 are the three most common classifications.

• M2 HSS
M2 HSS offers outstanding wear resistance because to its tungsten-molybdenum
composition after hardening. It has now displaced T1 the most popular high speed
steel grade due to its improved toughness & cutting capabilities. T1 is no longer
frequently manufactured or available in the UK.

• M35 HSS
Cobalt has been added to M35, making it more heat resistant than M2.

• M42
M42 tools have outstanding hot hardness & high hardness (ups to 70HRc), which
provide excellent dynamic performance in service.

 examples of bibliometric and scientometric data related to high

speed steel
 publication related to HSS by year

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 Which authors did most research on the HSS

 Publisher of HSS

 Most funding agencies behind the research of HSS

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Synthesis/manufacturing
 Synthesis
1. Raw materials
 Carbon: which boosts wear resistance.
 Tungsten and molybdenum: improve red hardness
 Vanadium: increases high temperature wear resistance
 Chromium: increases depth hardening
 Cobalt: enhances red hardness

2. Equipment
A high-speed steel mill has several conveyor belts, heaters, pumps, boilers and
reboilers, exhausts, motors, heat recovery units, pipes, cranes, and other standard machines,
just like any other industrial facility. These are standard tools needed in every kind of
manufacturing facility and are not just for high speed steel industry.

3. Processing conditions and post-processing step:

 Within a vacuum induction furnace, the steel was melted.
 The molten steel was poured into the tundish
 The flow velocity of the molten metal was roughly 0.5 kg/s, and nitrogen was
employed as the atomizing gas at a pressure of 1.5 MPa.
 A circular billet was created by cooling and accelerating the atomized droplets to a
substrate at a rotational speed of 90 r/min.
 The entire spray forming procedure took roughly 180 seconds to complete, form a
billet with a 200 mm diameter and 230 mm height.
 The billet was heated to 1150 °C for 3 hours, then forged using a forging ratio of 5 to
9 between 950 and 1150 °C, and finally chilled to room temperature mostly in sand.
 forged specimen was annealed for 4 hours at various temperatures.
 The specimens were then cooled to 700 °C at a rate of 10 °C/h, and cooling in air.

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 Manufacturing

1. Facility: - factory facility is needed for producing HSS

2. Processes: -
• Forging: -
It's important to avoid putting cold steel into a hot furnace while forging metal,
therefore heating must be done gradually and uniformly.
For initial forging, soak through at 1700–1800°F and then heat to 1900–2050°F.
Avoid forging at temperatures below 1600–1700°F, and after forging is finished, let
the metal cool gradually in lime, mica, dry ashes, or a furnace.

• Annealing: -
Heat gently to between 1400 and 1500 °F, then wait until the mass is completely
heated through before allowing it to cool in the furnace at a rate that can be raised
until it reaches about 1000 °F.

• Preheat for Hardening: -

Before charging into the preheating furnace, which should be running at 1350–
1550°F, warm slightly.

• Hardening: -
After sufficient preheating, move the tool to the hardening furnace, which runs at
2150–2225°F, depending on the application and the size of the tool.

• Quenching: -
Cool in a 1000–1100°F molten salt, oil, or air bath.
When quenching oil, it is often a good idea to remove the tool after the temperature
reaches around 1000°F and let the cooling proceed in still air.

• Tempering: -
Depending on the desired hardness, the tempering temperature may vary, but it
typically falls between 1000°F and 1100°F.
The use of two tempers is always recommended.

3. Scale of production: -
• The global high speed steel market is projected to expand at a CAGR of close
to 7% throughout the assessment period of 2021 to 2031 and cross a valuation of US$
4.5 Bn in 2031.
• Over the next ten years, M grade high speed steel will dominate demand with a
market share of over 40%.

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4. Most Manufacturing Areas

 Safety and Sustainability

1. Health hazards
• High speed steel tools product do not cause any inhalation, or other chemical
dangers during regular operation and usage.
• However, processes including machining, welding, cutting, grinding, and burning
of such goods could emit dusts, fumes, or vapors that could be harmful to your
health.
 Possible hazards
• Metallic dust and fume inhalation can irritate the eyes, nose, and throat.
• Skin contact irritation and rash occurs.

2. Exposure Control/Personal Protection

• Always wear safety glasses with side shields
• Protective gloves or barrier cream, and clothing to prevent skin hazard.

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 • To ensure that dust or fume concentrations do not exceed exposure limits, use
enough local or general exhaust ventilation.

Properties/
characterization
 Synthesis properties of HSS
A high carbon tool steel is high speed steel.
But because of its fantastic characteristics, it
is frequently used in the business. And
because high speed steel has a variety of
chemical compositions, there are various
kinds of it.

Composition of HSS
1.Tungsten(W) 4. Vanadium(V)
• increase the red hardness of steel.
• wear resistance in high temperature. • Hardened and tempered
Figure 1Chemical steels' strength
structure of HSS
and toughness are increased by
• enhance the stability of martensite
controlling grain growth.
decomposition at high temperatures.
• A smaller grain size helps to boost
2. Molybdenum (Mo)
ductility and tensile strength.
• decrease the solidification temperature
• Higher temperature creep properties
of HSS.
are enhanced by larger grain size.
• make the toughness of HSS get better.
5. Cobalt (Co)
• Throughout the tempering process,
• Boost high speed steel's secondary
avoid having the carbides separate out
hardness, high Temperatures hardness,
near the grain boundary.
and thermal conductivity.
• reduce the thermal conductivity of
• High speed steel's melting point could
HSS.
increase due to cobalt.
3. Chromium (Cr)
• Raise the hardenability, oxidative
6. carbon(C)
stability, and corrosion resistance of
HSS. • carbon is essential to the hardenability
of steel.
• make the hardenability and red
hardness of HSS become great. • Massive volumes of complicated alloy
carbides are necessary for the
• The rate of pearlite transformation's
wearability and high hot hardness;
crucial cooling is slowed down.
carbon plays a key role in this.

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• The Figure demonstrates how the significantly reduces the eutectoid's
addition of W, Mo, and Cr carbon content.

 Mechanical properties of HSS

Name High speed steel

Density 78160 kg/m3

Ultimate Tensile Strength 1200 Mpa

Yield Strength 1000 MPa

Young’s Modulus of Elasticity 200 GPa

Brinell Hardness 720 BHN

Melting Point 1430 °C

Thermal Conductivity 41 W/mK

Heat Capacity 470 J/g K

Price 8 $/kg

 Characterization technique

 Hardness testing by Vickers hardness testing

• Testing was carried out by utilizing of a Universal
hardness tester EMCOTEST Duravision.
• A dwell period of 15 seconds was used with a load
of 50 kg.
• In order to achieve a calibrated range of about 500-
750VHN, the calibration was confirmed with two
reference materials.
• At intervals of 15mm, the hardness was measured over the depth of the shell.

Figure 2Emcotest Duravision

11 | P a g e universal hardness tester
 • At each depth interval, ten measurements were made on all the samples.
 Scanning Electron Microscope (SEM) Analysis

• In order to characterize
the chemical
composition of both the
matrix and carbides and
any variations across
the shell depth, SEM
examination was
carried out using an FEI
Nova NanoSEM 230
high-resolution
scanning electron
microscope (HRSEM)
equipped with an
EDAX energy
dispersive x-ray (EDX) detector.
• During the analysis, a Figure 3Simple diagramFigure 4FEI NOVA NanoSEM
30kV accelerating of SEM 230 FEG
voltage was applied.

 Impact Testing

• Charpy V-Notch (CVN)

impact testing was used to
determine the Material
tensile strength and its
change with appropriate
heat treatment.
• An Instron SI-1M
instrumented impact
testing equipment was
used for the testing.
• The instrumented CVN
test would guarantee
correct comparison and
provide extra details regarding the energy of both crack initiation and propagation, not
just the general
characteristics. Figure 5Instron SI-1M Figure 6Simple
diagram of impact
testing

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 Application of HSS

 tools for cutting the other materials

Proposed model: -
• a section of the saw blade that is preferably made of a robust, fracture-resistant
material.
• A bimetallic strip consists of the
functioning component and the main
body.
• It is suggested that a bimetallic strip with
two edges that are at least essentially
parallel be used to make the saw blade.
• Any technique known to those
knowledgeable in the art can be used to
create the working edge with the set of
saw teeth, inc luding stamping, laser
cutting, and other cutting techniques.
• Additionally, it is suggested that the
working part's height be greater than the
set of saw teeth's height.
• Furthermore, it is suggested that the saw
blade be overlappingly attached to the
fastening component.

Claims of the intended application

 When the functioning part is defined by a second portion of the bimetallic strip, while
the main body is defined by a first section of the strip.
 where a spot-welded connection holds the main body to the attaching component.
 wherein the two different metals or metal alloys that make up the bimetallic strip are
physically bound together along the straight connecting edge.
 wherein the working edge's shape is symmetrical with respect to its mid-
perpendicular.
 where the connecting line resembles a parabola in shape.
 wherein the production of the set of saw teeth also produces at least one functioning
edge.
 where the straight connecting edge and the bimetallic strip are substantially divided
transversely.

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 High speed induction motor with a squirrel cage rotor having
end rings and non-magnetic spacers.
Proposed model: -
• A high-speed induction motor with a coaxially positioned rotor within the stator and
installed in a suitable frame with a water-cooled jacket is disclosed.
• The stator contains stainless steel end plates and a multiphase winding on a laminated
core.
• Layers of insulation are positioned between the windings and the cooling coils which
are positioned around the end turn parts of the windings.
• In order to form the rotor teeth between adjacent conductor bars, a number of
elongated conductor bars are fitted tightly into a number of semi-closed, elongated
slots in the rotor core. The slots and bars are preferably wedge-shaped in cross section
and have a narrow neck portion that is located adjacent to the rotor core's outer edge.

Claims of the intended application

 Bosses or gussets with four or more continuous bosses or apertures made of cast steel
or forged steel are present.
 Bosses or gussets strengthen the structure and maximize the strength of the
attachment places designed for fasteners, bolts, or rivets to be attached to a blade or
other item.
 Hub increases the stiff blade's area of contact with the hub while reducing blade flex,
out-of-roundness, wobble, and early failure or breaking.
 Hub is concentrated in size to enable optimum seeding depth without contacting the
depth wheel or depth wheel arm.
 High-speed planting necessitates increased down pressure and significantly increases
radial and rotational pressures; the hub is designed for this.
 Hub permits greater downward pressure pressures brought on by newly created
hydraulic and air systems.

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Conclusion

 A subgroup of tool steels known as high-speed steel (HSS or HS) is frequently utilized as
a material for cutting tools. It is frequently utilized in drill bits & power-saw blades. Its
ability to endure greater temps without losing their temper makes it superior to an older
high-carbon steel cutters that were widely used throughout the 1940s.
Tungsten, vanadium, chromium and molybdenum are the four main alloying elements
that create carbides in high-speed steels. Hard & wear-resistant carbide compounds are
created when these alloying elements react with carbon. High-speed steels have a
martensitic matrix and two sets of carbides dispersed throughout it as their
microstructure. The Charpy V-Notch (CVN) impact testing gives the Material tensile
strength and its change with appropriate heat treatment.
 Hard carbides must be held in a reinforced matrix in order to increase wear characteristics
while taking surface roughness into account. To achieve this, it is suggested that the
vanadium content be decreased, that alloying elements be added to cause solid solution
hardening, that fine carbides be precipitated to promote secondary hardening, and that
preaustenitization be used to generate minute previous austenite grains.
 At the end of this paper, I explained the three intended application of the high speed steel
and claims of those application all three applications clearly stated the high speed steel
have a wide variety of use in industry as well as in future also.

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